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    Thread: Billburt's DIY/build thread

    1. Moderator kilimats's Avatar
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      02-25-2012 02:24 AM #51
      remind me we should make a "not so cheap mods" and "maintenance" thread, the current DIY sticky thread has too many missing pictures and content IMO

      if you guys think it's a cool idea i'll go ahead and create those two thread following the same rules from the cheap version and make them sticky if the get a lot of valuable content

      Kudos to you Billburt for doign this thread , great pics
      Last edited by kilimats; 02-25-2012 at 02:34 AM.
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      Quote Originally Posted by dele
      The guys on coils can pull off their own Airless pride thread cos they clearly are the underdogs in the air/static debate, kinda like the equality movement for women.

    2. Member Billburt's Avatar
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      02-25-2012 04:27 AM #52
      Quote Originally Posted by kilimats View Post
      remind me we should make a "not so cheap mods" and "maintenance" thread, the current DIY sticky thread has too many missing pictures and content IMO

      if you guys think it's a cool idea i'll go ahead and create those two thread following the same rules from the cheap version and make them sticky if the get a lot of valuable content

      Kudos to you Billburt for doign this thread , great pics
      Thanks man, yea I would love to contribute to those. The next DIY im putting up is on the eurojet FMIC which to my knowledge has no good DIY at all.


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    3. Member Billburt's Avatar
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      02-25-2012 04:29 AM #53
      Quote Originally Posted by Bierce IV View Post
      Your mintex pads arent squeaky? Mine are loud as a bitch.
      They are as quiet as can be, and my last set never made noise either (knocks on wood).


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    4. Member Zach!'s Avatar
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      02-25-2012 04:29 AM #54
      Quote Originally Posted by Billburt View Post
      Thanks man, yea I would love to contribute to those. The next DIY im putting up is on the eurojet FMIC which to my knowledge has no good DIY at all.


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    5. Member Billburt's Avatar
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      02-27-2012 10:26 PM #55
      DIY for eurojet FMIC will be going up tonight. I finally got around to uploading the photos
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    6. Member Niagara_V_Dub's Avatar
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      02-28-2012 01:47 AM #56
      These plates are on my list of to do's once I FINALLY (been piecing it together slowly over the last few months) and while I am at it might as well do the brakes, rotors and bearings too. Reall clean looking car though.

      This thread is the wind beneath my wings.
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    7. Member Billburt's Avatar
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      02-28-2012 01:59 AM #57
      and now for the Eurojet Street FMIC install. I'm truly sorry in advance for this one will not be as detailed in term of pictures but, I will try my best to make up in text description. I must say that this is my second time installing this intercooler system and I am pleased to say that it has gone better this time and I have found it easier and cleaner than the latter.

      I must once again thank Ryan V., my brother, and Christian P. for helping me with this install.

      You will want to jack the car up and put the fronts on jack stands. You must begin by removing the front bumper. some may wish to take the front wheels off in order to better access the front wheel well cover screws, but with the proper tools it is not necessary.

      the engine bay before


      Then take the front grill and lower side grills out. the front grill can be removed by popping the hood and utilizing a screw driver for popping off the metal retaining clip and twisting the screw driver to pop loose the plastic hood latch pull. once that is done you can pry from the top of the grill towards you and carefully pop out the grill from the bumper. The lower side grills can pop off with no tools and the use of your fingers. Press down on the left and right sides of the grill where the slits are. my thumb displays where to apply pressure for the left side. It should pop right out with no trouble at all.





      Now that the grills are off it is time to remove the bumper cover. you will need a torx bit set because there are two different sizes needed in order to remove it. if my memory is correct there are 5 in the area below where the grill is, one behind each lower side grill and three on each side holding the bumper cover to the wheel well covers. all are pictured below being removed. Once all 13 screws are removed you can (with the aid of an extra set of hands) safely remove the bumper cover; it should just slide off. As the bumper is sliding off you will need to un-plug the side marker bulbs and if you have a special edition that reads outside temp you will need to un clip that as well which simply slides off. the bumper cover is then free to be removed and set aside safely.







      Now that the bumper is removed the removal of the front beam and stock side mount intercooler can begin. I would suggest by starting with the removal of the front beam. This might seem like a rudimentary task but it is far more difficult than it seems. There are two bolts and two screws per side. Each one of these plays a very important roll in holding a different portion of the front end together. Once the beam is removed you will notice that the front end has sagged. Unless you re-bracket the new (eurojet) front beam in the same position as the OEM one your bumper cover will not fit properly, the hood latch may not latch the hood as easily as before. Essentially you will need to fine tune this in order to ensure proper fitment. We adjusted it several times and opened and closed the hood multiple times until it was found to be as close to original as possible. Unfortunately when I purchased this kit used it did not include the Eurojet rebar (front beam), so I had to make due with the my old rebar from my old car and ground the plates off the OEM front beam and painted them so that I could continue to hold my front end together. I have included a photo of the Eurojet rebar for you to know what it looks like if you have not purchased it yet.




      test fitting the brackets

      In this photo you can see the painted brackets I have made from the old beam.


      The images of the Eurojet rebar as promised


      Uploaded with ImageShack.us



      And now it is time to remove the side mount intercooler. we started by removing the piping in the back of the engine bay that starts at the top of the turbo and heads down the passenger side to the intercooler. after the intercooler a pipe goes up to the side of the intake manifold which can be seen from the engine bay. All of these pipes are very easily unbolted/ unclamped to be removed. This is where I was unable to photograph some of these parts. I have been recovering from an internal injury and am unable to climb under the car to record that part of the removal process.

      It is important to unclamp and disconnect the diverter valve and all the other hoses related to the turbo inlet pipe as well as the top pipe that comes out of the turbo, because all of it will be re-routed.



      then you can unclamp the the top pipe as well as the pipe that heads down towards the pancake pipe which leads to the intercooler.





      This is the pipe that heads down towards the bottom of the car towards the pancake pipe


      If you would like to clean up the engine bay a bit more there are two of these pipe supports that are no longer needed and can be unbolted very easily.


      The next pipe to remove is the pancake pipe which can be removed from under the car in the front passenger side behind the wheel. once removed the bracketing for the side mount can be un-done. Before removing the intercooler it is important to unscrew the MAP sensor from the body of the side mount so as not to pull and damage the wiring. The hose between the side mount and the intake manifold in the engine bay can remain inside and attached to the intake manifold for it will be re-used with the eurojet FMIC. it may be difficult to keep it in there while removing the side mount so if is possible to remove it with the side mount and put it back in (as I have done).

      the pancake pipe removed


      the plastic side mount duct being removed



      The side mount being unbolted and removed








      NOW that everything has been removed from the old system you can now begin to install the new FMIC. I started with the mounting of the front mount itself in place on the front of the car. i have painted the front of the intercooler with semi-flat black paint to add for a stealth look and avoid ruining the clean look of the front of the car


      I would recommend that you start with the pipe in the engine bay and the routing of the boost hoses underneath it. The new routing is slightly different. The pipe from the turbo no longer goes to passenger side but now goes up and over towards the drivers side and down next to the battery so as to reach the right side of the intercooler. this portion is a bit tricky because you need to take an OEM hose you removed and cut it down to the right size for the diverter valve to reach the intercooler pipe. Below you can see the routing I have done. It is a very tight fit but it will work until I do the emissions delete which will once again simplify and clean the engine bay.




      Attaching the intercooler pipe to the turbo








      After this pipe there are two more for this side: the one that goes down and turns towards the outside of the car and the "U" shaped pipe that turns the routing to attach to the intercooler. below are the photos of this side being attached to the intercooler. NOTE: a hole must be cut out in the plastic splash guard so that the piping may go through to the intercooler. You also must make sure every clamp is properly set on the proper side of the bead and tightly secured. YOU WILL blow the pipe loose if it is not properly secured. you will also want to make sure every clamp screw is easily accessible in case you do blow a clamp loose or need to work on the car.



      In order for the pipe to clear I flipped the top horn on it's bracket and turned the lower one.



      The last thing to do is to secure the passenger side piping between the hose attached from the intake manifold in the engine bay and the right side of the intercooler pipe.

      NEW MAP SENSOR LOCATION


      NOW that all connections are complete i urge you to go back and check every clamp and connection there is in the system prior to putting the bumper back on. with this intercooler and piping it is not necessary to do any trimming to the bumper; it should slide back on properly and everything should go back on as it was before the installation. I am very pleased with the way it turned out as well as the fact that the cars modifications remains stealth.



      Last edited by Billburt; 06-21-2012 at 01:31 PM.
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    8. Member rains's Avatar
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      02-28-2012 02:27 AM #58
      now is inspired

      LULZ

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    9. Member Billburt's Avatar
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      02-28-2012 10:16 AM #59
      Hopefully the next DIY will be the emissions delete/engine bay cleanup. I'm just waiting on 034 to send us the silicone hoses we need. if they get here this week we will start Friday night.


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    10. Member Oly1975's Avatar
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      02-28-2012 10:51 AM #60
      I love this thread. Thanks Billburt
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    11. Member pGLi's Avatar
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      02-28-2012 12:31 PM #61
      helpful DIY
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      Quote Originally Posted by 87vr6 View Post
      having a car and not driving it to keep miles off of it for any future owner is like having a girlfriend and not screwing her so she doesn't get worn out for her future boyfriends...
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      02-28-2012 06:20 PM #62
      Lol that side mount wasss Sloopyyyy

      Some day we'll do a bagging DIY for mkivs mkvs Mr. W.

    13. Member Billburt's Avatar
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      02-29-2012 12:11 AM #63
      Quote Originally Posted by Loud View Post
      Lol that side mount wasss Sloopyyyy

      Some day we'll do a bagging DIY for mkivs mkvs Mr. W.
      indeed we will
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    14. Member Zach!'s Avatar
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      03-01-2012 01:55 PM #64
      #FlossFilthy
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    15. Member Dutchmastr9's Avatar
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      03-03-2012 12:38 AM #65
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    16. Member .Ant's Avatar
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      03-03-2012 01:46 AM #66
      I'm new and I would like some inspiration.
      Quote Originally Posted by Mr. Rictus
      Don't bomb threads with any variation of any combination of letters, numbers, words, phrases, icons, smilies, memes, pictures, videos or any other sort of post.
      Maintenance is paramount.
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      03-03-2012 02:30 AM #67
      wait your handing out inspiration for free??

      looking good duder

    18. 03-03-2012 03:02 AM #68
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    19. Member Billburt's Avatar
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      03-03-2012 10:26 AM #69
      Quote Originally Posted by .Ant View Post
      I'm new and I would like some inspiration.
      maintenance is paramount is about the best I can give you


      Quote Originally Posted by senad187 View Post
      wait your handing out inspiration for free??

      looking good duder
      rare around these parts haha thanks man
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    20. Member Billburt's Avatar
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      03-03-2012 10:31 AM #70
      some updated camber shots

      come at me bro!











      and this was the before

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    21. Member Pasquallies's Avatar
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      03-03-2012 10:44 AM #71
      very nice thread, I hope someone will do as good as a job with a vr soon..
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    22. Member Naters10's Avatar
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      03-03-2012 11:06 AM #72
      Great thread! Car's fitment is $$$. nice work

    23. Member livinzlyfe's Avatar
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      03-03-2012 10:16 PM #73
      your car is so ****ing clean. seriously. I am jealous. and thank you for posting the before and after shots of the plates. I will be ordering some next week.

    24. Member RmL1.8T's Avatar
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      03-03-2012 10:50 PM #74
      This thread is awesome! Mucho props

    25. Member Billburt's Avatar
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      03-04-2012 02:43 AM #75
      Quote Originally Posted by Naters10 View Post
      Great thread! Car's fitment is $$$. nice work
      thanks man, I'm working on it. Camber up front is next goal.

      Quote Originally Posted by Pasquallies View Post
      very nice thread, I hope someone will do as good as a job with a vr soon..
      unfortunately I do not have a VR otherwise I would do that as well.

      Quote Originally Posted by livinzlyfe View Post
      your car is so ****ing clean. seriously. I am jealous. and thank you for posting the before and after shots of the plates. I will be ordering some next week.
      for sure man np. hit me up if you have trouble with the install


      Quote Originally Posted by RmL1.8T View Post
      This thread is awesome! Mucho props
      thanks man
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