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Greyt 09 6spd build thread... (long overdue)

271K views 2K replies 155 participants last post by  thygreyt 
#1 · (Edited)
o-ring size: #226 buna
wvw ev71k 77w 048389
3vw jm71k 39m 097803
NGK BKR7EIX-11 @ .028"

currently:
Car

Engine bay

cabin


mods for thy greyt .:R25
PERFORMANCE



Engine mods


:yes: Neuspeed power pulley
:yes: Eurojet valve cover
:yes: Custom exhaust. (part of it is 3" and parts are 2.5")
:yes: United Motorsports custom Software
:yes: United Motorsports intake manifold
:yes: water meth kit: DVC-30
:yes: Custom 3.0" intake with heat wrap and DEI spray paint thermal coat
:yes: Custom turbo kit (specs below)
:yes: completely heat painted and heat wrapped exhaust


Engine Cosmetic parts:

:yes: JCaps Billet Aluminum Oil Cap
:yes: JCaps billet Aluminum dipstick cap
:yes: polished manifold -> march 2012
:yes: polished timing cover
:yes: polished valve cover-> june 2010
:yes: Custom painted black throttle pipe
:yes: polished oil cap
:yes: relocated the harness by the coolant bottle
:yes: removed the SAI combi valve, pump, system.
:yes: most wire tucking

Engine Build parts:Installation pending

:yes: stage 2 ferrea valvetrain.
:no: Forged rods
:no: 8.5:1 forged pistons
:no: head gasket
:no: Main bearings
:no: rod bearings
:no: head studs
:no: main studs

Turbo kit parts

:yes: SPA t3 turbo exhaust manifold (cast log style)
:yes: 39mm TIAL wastegate
:yes: TIAL Q BOV (silver spring)
:yes: 550cc Bosch injectors
:yes: CTS Intercooler 450HP
:yes: PTE 5858 .82 A/R, t3, v-banded exhaust, 3" inlet, 2" outlet.
:yes: 3.0" v band stainless steel downpipe- Cat-less [custom]
:yes: Eboost 2
:yes: Heat protected oil feed line
:yes: Turbo heat wrap/cover
:yes: Rocket launcher switches to control boost levels
:yes: paint and heat wrap downpipe
:yes: Paint and wrap intake pipe
:yes: Custom open dump. Thermal painted and wrapped. (39mm)

Drivetrain

:yes: 6sp MT tranny swap
:yes: Forge short shifter
:yes: 42dd bushing kit
:yes: HPA Motorsports 85a Core Interlock Mount
:yes:BSH Billet Motor mount
:yes: BSH Billet Pendulum Mount
:yes: bsh transmission mount
:yes: OEM clutch and pressure plate
:yes: Four season tuning flywheel
:yes: Wavetrack LSD



SUSPENSION

:yes: Neuspeed rear sway bar
:yes: Neuspeed Front sway bar
:yes: Neuspeed rear endlinks
:yes: H&R street performance coilovers
:yes: ABD rear Stress bar (inside trunk)
:yes: battery relocated to trunk(optima red top D35
:yes: Whiteline anti-lift kit
:yes: corner balanced car
:yes: H2 Sport Camber Plates
:yes: tyrol sport deadset rigid subframe



BRAKING


:yes: continental Extreme Contact DW tires 245/40/17
:yes: drilled/slotted rear rotors (oem size)
:yes: hawk breaking pads hps (rear)
:yes: custom painted brakes [black]
:yes: Porsche brembo brakes [front, from cayman]
:yes: Slotted 312mm rotors [front]
:yes: Brake fuild: super blue


Visuals

INTERIOR {to do}


:yes: OEM euro dash tray
:yes: OEM euro switch
:yes: OEM GLI aluminum pedals (+ footrest)
:yes: OEM golf ball shift knob
:yes: OEM .:R- Line steering wheel
:yes: OEM dash cubby
:yes: OEM Euro Switch
:yes: Rear seat Delete
:yes: Pioneer avic U310-BT
:yes: INNOVATE motorsports wideband AFR
:yes: New South Mech boost gauge
:yes: New South steering gauge pod
:yes: OSIR AC gauge pod
:yes: Valentine V1 hardwired
:yes: Blinder 905 HP (dual front) hardwired
:yes: JL Audio amp: G4500
:yes: focal speakers (165 A1 and 165 A3)
:yes: Focal 10" subwoffer 25 A1
:yes: JL j2 250.1 mono amp.
:yes: sound system rewired with AWG 12 oxigen free audio wires
:yes: Monster Cables RCA from: head unit to g4500 (16ft) and from g4500 to j2 250.1 (3ft)
:yes: Pioneer Avic U310BT
:yes: Sound insulated front door skins, trunk and under the rear seats.
---------------------------------------

EXTERIOR

:yes: OEM GTI front euro lip
:yes: OEM GLI side skirts
:yes: OEM Rear GLI valence
:yes: OEM 3 piece lip spoiler
:yes: OEM Black Magic Pearl sideview mirrors
:yes: OEM wolfburg ed. front grill
:yes: OEM Bixennon Headlights
:yes: OEM Euro LED tail lights with rear fog
:yes: Rieger roof spoiler
:yes: 15%tints
:yes: short antenna
:yes: custom painted valence reflectors
:yes: custom painted rear VW emblem
:yes: custom painted side markers
:yes: custom painted LED Tails.
:yes: Wheels plasti dipped: orange blaze

------------------------------------------------------------------------------------------------------------------------------------
======================

stage 3 of the build:
is engine build time, 1200 cc injectors, fuel pump and push it to turbo limit. And maybe change the turbo or hotside to a .63

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
well, here it is...for me to "Finish" the car on its current stage i need to do the following:

Mods planned, yet i'm done. Maybe? these are maybes, track dependant
-Sparco seats for better track time
-Wheel Studs
-Oil cooler

Engine mods:
Max out injectors
6 port injected meth, and 1 before the ic or right after.
Re do the intake manifold.


X. Rear GLI brakes
X. Audi TT RS control arms and bushings (for whiteline's anti lift)
X. Custom 3.0" V-Banded exhaust Quad


==========
THEN, the GOOD mods:

-AWD swap.
-----front and rear LSD
-----all the mods for the drivetrain.-I doubt this.

-Interior:
-----seats
-----harness
-----steering wheel
-----lil misc fun things

-Turbo:
-----maybe upgrade to a v-band and custom tubular manifold.
-----maybe upgrade to 60xx or 62xx turbo or a 58xx with a BB

-engine build:
-----Ferrea valves
-----forged pistons 8.5:1
-----Forged rods
-----ARP headstuds
-----complete rebuild (new main bearings, new headgasket, hone and polish, etc)
 
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#650 ·
I'm excited for your turbo project and seeing those results.

Slow and steady for me, I know what you mean about not having money. I finally ordered my last pieces for my suspension. Easy and a little drop. Koni's with Neuspeed springs going on the car in a few weeks after all of my pieces arrive. Slipped my torque insert in today, hoping to feel that difference in the next few days.
 
#652 ·
man its been a while since i looked at your build, but its looking shiny =]

i too would be worried about the way you're venting. what happens if that vented vapor ignites? wont it just go back to your gas tank without proper valving etc?
 
#658 ·
wow... um... i'm wondering about my turbo choice! lol... the car might just be TOO powerful! :D

so much fun...

here you have some numbers.



on a 1.8T, it made 397WHP
on another 1.8T it made 456 whp
on a 2.0 FSI it has made ~600 whp
on a 1.8T 341whp at 23psi

i made over 400whp consitently on a stock awp head on pump @25psi.. i did have an SEM/80mm tb and ran a bit lean, due to unfinalized tweaks
575 crank on 22psi / q16 with the 5857 and our bigger hydraulic / street grind. Full boost around 4300, or thats when torque comes up anways.

That's with an air to water set to 120 degree F IAT's.

Nice street turbo. :thumbup:
I have looked and looked for 5857 dyno's myself. I'm currently building a 2.0 5857

the only dyno of 034s car i have seen


A 1.8 5857 on maestro

A 5557 which spools nearly identically to the 5857, just not as much power up top
awd 2.0 on a Custom ME5 tune by 034
[/QUOTE]



http://forums.vwvortex.com/showthread.php?5464901-My-Build-Thread-1.8-PAG-VBAND-KIT-5857-DBB

http://forums.vwvortex.com/showthre...work-in-progress...-My-Custom-BT-build-thread

http://forums.vwvortex.com/showthread.php?5107559-5857-dynos
 
#668 ·
i think i have finally decided on the wheels:

OZ/sparco Pista.

it looked good on Will's .:R (germanbycar):



they are 22lbs, SUPER CHEAP, 18*8 and "flat.".. did i mention an offset of +48? :D everything i want! :D :D :D
:wave: Hey dude.

In all the pics above I had 235-40's on them. No problem.

The wheels themselves I loved. Couldnt beat them for the price! I also loved the color.

Cleaning them wasnt exactly fun, but worth it! Solid wheels.
 
#671 ·
i leave for a couple months and this is what you do?! haha. lookin good man. Definitely sunk a hefty bit of coin into that, but it looks great.

those Pista wheels will look awesome on your car. I'm a sucker for dark wheels.

Pardon my newbness, but removing the lines and such, but what do you do with them and/or re-route them. the 'clean look' is awesome. Less is more.
 
#672 ·
i leave for a couple months and this is what you do?! haha. lookin good man. Definitely sunk a hefty bit of coin into that, but it looks great.
lol, spent money?? where? and thanks! i have spent HOURS and lbs of sweat into it... :heart:

those Pista wheels will look awesome on your car. I'm a sucker for dark wheels.
i like em a lot too... i have had MANY sets of wheels now.. and this wheels meet all my requirements.
my last set (BBS) and the one before them werent that good... i mean, reps are reps and i didnt fully love the BBS.

with the Pista's i can bend em and buy more! lol... they have a GREAT offset +48... and i might even space em out to a 42...

i could also paint them white! :D who knows!
or golden..? :D

Pardon my newbness, but removing the lines and such, but what do you do with them and/or re-route them. the 'clean look' is awesome. Less is more.
lol, i DELETED the lines.. as in, they are now in a box...! :D you cap off the vacuum ports. and use proper resistors on the wires to avoid cels and maintain readyness. :D
 
#674 ·
Lol.. I know, i saw.

You did boxter fronts?? Awesome!! Ill be doing gti fronts for now, and post turbo ill do the same!

Im actually at 24.5" and on 225/40/18 et 42. And i drove on the helen mountains taking turns at 60 and no rubbing, at all.
Yes, screw is long gone.

I also sort of know how to delete some of the crap, or relcate it. Let me know when you want to play!

Sent from my GT-P7510 using Tapatalk 2
 
#675 ·
You did boxter fronts?? Awesome!! Ill be doing gti fronts for now, and post turbo ill do the same!

I also sort of know how to delete some of the crap, or relcate it. Let me know when you want to play!

Sent from my GT-P7510 using Tapatalk 2
Yeah. i used my super jew powers and got everything on the cheap. the rotors i got were NIB and basically free. they are cheap rotors, but still function. I'm plannin on doin adamsrotors soon enough, but since i just did these, i'm in no immediate rush.

I was able to get front and rear HPS pads for $150 shipped, NIB. such a steal, but had to wait a few wks more than expected, but was no biggie. Go with ATE Super Blue (helps a lot with bleeding) or you can go overkill with Motul RBF600. Either way, it will likely be more power in fluid than you will ever really need, if youre not tracking. Calipers themselves we about $275, then rebuilt them out of safety and 'just in case' purposes (another $150), painted em with G2, SS lines (use goodridge or ECS, i've found Technafit [the ones USP sells] works up front, but has a weird fitting in the rear that wont hold the C-clip.). Picked up Apikol carriers used (may still have a set available) in the B6 classifieds as they are the same part no, they simply dont need the shims/spacers as B6's do. Oh, and don't forget new banjo bolts.

I have all the part numbers posted up in my build, just in case anyone wanted to know.
 
#680 ·
Those wheels look nice. I really like "motorsport" wheels with many spokes. I REALLY wanna get a set of the VW Motorsport wheels myself. Can't wait to see some pics of those on your car.
Agree.. I like the vw motorsport wheels too, but on 18s they are only 7.5 wide... And I need at least 8 to run 245/35s... Hence the sparco wheels.

Sent from my HTC Sensation 4G using Tapatalk 2
 
#682 ·
lol.. so much fun today! :D

i have no clue why, but it seems like when i lower my windows, no music and no AC, i can driver PERFECTLY! :D

i mean, super smooth, quick and fun! its like the car changes!!! :eek: i cant even begin to express it!!! its awesome!!!

for the first time in a couple of months, i was plesantly surprised with the car! i mean, i was used to the power from UM... and its like somehow i just got a couple extra ponies.

well, drove 120 miles today... i may do some lil things on the car this weekend.. like WASHIG IT! lol.

happy panda is happy.
 
#685 ·
for the first time in a couple of months, i was plesantly surprised with the car! i mean, i was used to the power from UM... and its like somehow i just got a couple extra ponies.
im still loving my tune! it has been a good 10k and its been odd, but i think my gas mileage is getting better as the car ages lol. it wasnt a drastic change, but i noticed i have been slowly getting better range on each tank. and my mpg is rising to about 26-27 in the city with my same driving habits.
 
#697 ·
I haven't checked this thread in months, been following your posts on mkvjetta forum but you stopped updating it so I thought you might have gotten rid of the car.

what kind of awd system are you planning on using? what type of diffs for front, rear and center? how's the turbo project coming along?

You guys gotta help us out with mpgs my wife is getting 18-20mpg city and 25 mixed on the streets of miami beach, no where near the 27 city some of you have mentioned. :what:

maybe you guys can recommend a shop to me near miami beach so I can get some work done to this car in the future - some cosmetic work, wheels, suspension, headlamp install and some kind of engine tune. don't want to go to gunther anymore for work.
 
#700 ·
currently living in pompano (exit 36 on i95...) but will be moving to weston by the end of the month! :D

so that will make things easy! :D just take sunrise to 869 (swgrass expressway) south untill 75, and exit on royal palm!

i'm doing an oil change on a mk4 2.0 next week, and a vacuum delete (all hoses, etc) on a 1.8T that will be going Big turbo soon! :D
 
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