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    Thread: The Long & Winding Road - MKV Version!

    1. Member meechelle's Avatar
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      Jul 20th, 2009
      Location
      Chelmsford, MA
      Posts
      2,908
      Vehicles
      2009 A5, 2007 GTI, 2003 GLI, 2002 TT, 1987 Cabriolet
      09-02-2012 04:00 PM #1
      I figure it's about time I got this together and posted - Bear with me while I get this organized

      Build List
      Engine/drivetrain
      Garrett GT3071R
      Tial 44mm wastegate
      4 angle competition valve job
      Stage 1 port
      Cylinders bored
      Block squared & decked
      Assembly balanced
      Crankshaft micropolished
      Hand filed piston rings
      Ferrea 1mm oversize intake & exhaust valves
      Ferrea lifter shim kit
      Supertech titanium valve springs & retainers
      Wossner forged pistons 83.50mm, 9.2:1CR, 92.8mm stroke
      Scat steel H beam rods, 144mm 20mm pin
      Integrated Engineering valve guides
      Integrated Engineering timing belt gear dowel pin kit
      ARP crank damper bolt
      ARP head studs
      ARP main studs
      Calico coated race rod bearings
      Calico coated race main bearings
      Golf R DV setup
      Custom 3.5 inch intake piping
      Custom 3.5 inch charge piping
      New OEM lifters
      APR HPFP
      RS4 injectors
      RS4 fuel return valve
      TT-RS in tank fuel pump
      RS3 Fuel delivery control unit
      BFI stage 2 motor mount and transmission mount
      Eurojet CNC valve cover – powdercoated translucent blue
      Eurojet VTA catch can – powdercoated translucent blue
      Eurojet FMIC
      ATP 3” DP A3 Quattro
      Custom SS 3” catback
      Snow stage 2 water/meth kit
      42 Draft Designs oil pressure relocation kit
      42 Draft Designs Shifter Bushings
      Forge shortshifter, front to back & side to side
      TT AWD 02M Transmission
      Quaife LSD
      Custom stage 3 endurance clutch
      Raxles bulletproof V2.1d axles

      Suspension & Brakes
      Koni coilovers - Height and dampening adjustable
      A3 Quattro front & rear swaybars
      R32 brakes, front & rear
      USP Motorsport SS brakelines
      S3 control arm brackets & bushings
      Whiteline rear trailing arm bushings
      Whiteline front & rear adj swaybar endlinks
      VMR V710 18" wheels

      Cosmetic
      Smoked side markers
      Smoked mirror turns
      Smoked tails
      Black front emblem
      Fog light open grilles
      Rear wiper deleted
      Shark fin antenna deleted

      Interior & ICE
      Corbeau front seats
      Rear seat delete
      Pioneer AVH-P4400DVD 7" screen
      Euro dash tray
      Euro headlight switch
      NewSouth boost gauge
      NewSouth oil pressure gauge
      AEM AFR gauge
      AEM water/meth failsafe kit w gauge


      I took delivery of my Black Magic Pearl 2007 Package 1 6MT GTI July 14, 2006. I chose Package 1 because I wanted the Interlagos plaid seats. I had my choice from the first 3 2007 GTI’s my local dealer got, there were 3 Package 1’s in black, red and white. Looking back I wish I had picked white, but oh well I do like the black it’s just hard to keep black looking good. The only option on the car was the 18” wheels with summer performance tires. Sticker price was $24,850.
      At first I didn’t want to change anything about the car, but we all know how that goes…
      In the beginning! Completely stock and monster truck tall



      First mod was lowering springs - May 2008



      Second mod - REVO stage 1 flash - July 2009 @ Waterfest - it was at this point I was totally hooked with modding the car. I also picked up a Eurosport intake at Waterfest.



      New APR SS DP & SS GHL catback exhaust - August 2009




      VMR V710 wheels made a huge difference in appearance - H2oi - September 2009



      Encourage 2.0T FSI cam follower awareness! Basically I upgraded to an APR hpfp and had just read about the cam follower issue on this motor so I thought it should be checked just in case when the new hpfp was installed and this is what my cam follower looked like! It also wore the plunger off the old hpfp and ruined the intake camshaft. This necessitated replacing the follower, intake cam (with an upgraded hardened 'b' version) along with a cam chain tensioner that was also broken. I don't know how, but the car still ran fine. - February 2010



      Koni coilovers and H-Sport front and rear swaybars were installed in time for WiTW and went REVO stage 2+ - March 2010

      R32 brakes all 4 corners - July 2010



      I picked up some OZ Mito's off the 'tex for decent money and ran them for some of 2011, I like the stanced look but it wasn't practical for running the twisties which is what I like to do with the car

      Trying out the fitment of the OZ's - needed all 4 degrees of negative camber in the rear





      Dustoff 2011 rollers - thanks Seth and Krissy





      Eurojet CNC valve cover and catch can powdercoated in translucent blue - September 2011





      At H20i 2011 some douche-nozzle keyed my car and a friends of mine's car at the Astoria on the Sunday night a full week prior to the show. Insurance gave me a whopping $888 to fix the quarter panel, door and fender on the passenger side. Full vinyl wrap was chosen as it was either the motor build or a full respray this winter. In a couple of years I will either repaint the car BMP or go for a full color change.

      I started accumulating a few things as sales pop up in the fall of 2011 around the holiday season such as a EJ stock location FMIC and BFI motor mounts



      Last edited by meechelle; 07-26-2015 at 05:38 PM.
      GSE - Granite State European
      flickr - ig: meechelle_k

      My GTI Build Thread - The Long & Winding Road MKV Version!

    2. Member meechelle's Avatar
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      09-02-2012 04:00 PM #2
      Winter/Spring of 2012 the BT motor build begins and the car gets wrapped in matte black vinyl


      I decided to go big turbo and chose the ATP hardware kit with the GT3071r as the foundation of the build. At first I was thinking I would just build the head because at the minimum I would have to have the head apart to clean all the carbon build up on the valves that is another common issue with the FSI motor. In talking to a few others on the ‘tex who had done similar builds and my local VW friends, I was convinced that if I was opening the motor up I might as well do the bottom end at the same time. I set my budget at 6K (I was so naïve!).


      My ultimate goal for this build is to have a car that is road course track worthy, yet still streetable. I set my horsepower goal at ~500whp and am going with a fully custom tune from United Motorsport.


      I had planned to run out the rest of the year on my stock clutch, but after pulling the motor and taking the transmission off found that there was enough wear (car now has roughly 122k) that it didn’t make sense to put the stock clutch back in. So I ordered up a South Bend stage 3 Endurance clutch. Then I decided that if I was going for a new clutch I should probably get an LSD. I chose a Wavetrac based on their biasing and was lucky enough to get in on a group buy over on the mkvgti forum.


      Seth J did an amazing job on the vinyl wrap



      Ryan & Blake pulled the motor out - February 2012 - and I spent about 3 hours with several spray bottles of Simple Green and a toothbrush scrubbing the crap out of the bay.



      Old stock pistons are filthy



      New Wossner pistons are gorgeous!!!





      I chose R&L Engines in Dover, NH to do my machine work based on their reputation for meticulous work and many recommendations from friends who had work done there. Again I was very naive regarding what machine work would need to be done to my motor to achieve my goals and after talking at length and in great detail to Leo at R&L realized that I would need about 3x my original machine work budget. So now with this and the new clutch and diff I raised my budget to 12K.


      Block is back from R&L - April 2012



      The rest of the motor is back as well - just in boxes! - April 2012 :shock:



      Had East Coast European in Greenland, NH assemble the block and head - May 2012 - Awesome service at East Coast, they were on point with estimated cost and time and did a thorough job. Or so I thought at the time



      And Blake has put some of the other stuff back on the motor



      From the turbo side - still not final position but you get the idea



      Blake installed the front adjustable sway bar end links and the rear adjustable sway bar end links are waiting to go in (had to source a 14mm triple square of the proper length)





      All was going fairly smoothly, if a bit slowly up until the diff install. I got several recommendations for a transmission shop to install the Wavetrac LSD in my transmission. This transmission shop in Plaistow, NH shall remain nameless, but lets just say they couldn't have been more incompetant. The transmission was there about a month and a half and they assured me they had done several LSD installs in O2Q transmissions. They insisted that Wavetrac had sent me the wrong LSD. I got a hold of Wavetrac and gave them the phone number to the transmission shop. They went back and forth for several weeks with Wavetrac (Autotech) bending over backwards trying to help them put the LSD in correctly. Finally the transmissin shop called and told me they just couldn't do it and it I would still have to pay them for their time.

      In the meantime Wavetrac asked me to mail them my stock LSD and the Wavetrac LSD. I sent them off to California from Massachusetts. Wavetrac called me up and said the LSD was the correct one, but that the transmission shop had ruined both bearings on the LSD by hammering them on. Wavetrac graciously replaced the bearings for free and offered to arrange for a local distibutor in the Boston area to install my LSD. I honestly can't say enough good things about the superb customer service from Wavetrac/Autotech!

      When the diff arrived back in the mail, I hauled it and the disassembled transmission off to Shine Racing in Attleboro, MA. Anyone in the New Engalnd area knows that Dick Shine is a legend in the VW/Audi racing world in the North East. Dick opened up my transmission case and found that the shop in Plaistow had tried to split the case without removing the thowout bearing by prying it apart. That transmission shop had also ruined every shim and race bearing in the transmission and managed to bend the reverse shift fork. The transmission case was so damaged that it needed to be decked so it could be put back together without leaking like a sieve.

      Shine Racing had my transmission completely rebuild and the diff installed in just over a week and that was only because they had to wait for parts. This was a very expensive lesson learned on my part. Just because a shop is recommended and says they know what they're doing doesn't mean they're any good. So now basically 2 months was wasted because of the nameless transmisison shop in Plaistow and my diff install cost $1400 - FU Plaistow Transmssion shop!




      Motor is back in the car end of August 2012 but tons of stuff remains to be finished such as installing the water meth, axles, finishing the battery relocate wiring, finishing the gauge wiring and deciding how to run the dump valve






      September 7th, 2012 - Had the car towed to my friend Josh's shop yesterday so he could vband the new dp to the old ghl cat back. Had to tow it because the bleeder for the clutch took a dump and the part was of course special order.



      V-banded exhaust work by Josh



      Raxle



      Passenger side charge pipe



      Motor looks more together, but still needs a good cleaning!





      9-15-2012
      Front bumper is wrapped and I put about 100 miles on the car today to start breaking in the motor! The drive went well. I'm still getting used to the clutch and such but boy does it really move even just on the base tune. Still not sure if I'll be on a base tune or final tune for H2o



      Last edited by meechelle; 03-12-2015 at 10:51 AM.
      GSE - Granite State European
      flickr - ig: meechelle_k

      My GTI Build Thread - The Long & Winding Road MKV Version!

    3. Member meechelle's Avatar
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      09-02-2012 04:00 PM #3
      Future plans

      which include for winter of 2013/2014:

      HEP stage 3 manifold with secondary fuel rail
      secondary injectors
      IE Surge tank
      bigger oil cooler

      and probably a rear seat delete
      Last edited by meechelle; 06-06-2013 at 01:43 PM.
      GSE - Granite State European
      flickr - ig: meechelle_k

      My GTI Build Thread - The Long & Winding Road MKV Version!

    4. Member bryangb's Avatar
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      09-02-2012 09:35 PM #4
      // Open Road Tuning
      Instagram: @bryangb
      bags and wheels = build thread

    5. Member
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      09-02-2012 09:47 PM #5
      EJ cover on a fsi? How?

      Sounds like its going to be fast! Very nice!

    6. 09-02-2012 09:55 PM #6
      Mmmmm do far so good
      Ryan Gravelle
      club.broke.status : flickr

    7. Member bryangb's Avatar
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      09-02-2012 10:36 PM #7
      Quote Originally Posted by RomanML320 View Post
      EJ cover on a fsi? How?
      // Open Road Tuning
      Instagram: @bryangb
      bags and wheels = build thread

    8. Member Getaway Car's Avatar
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      09-02-2012 11:56 PM #8
      Head work

      Curious to see some dyno results
      Get yourself a car, drive it all alone...
      Get yourself a car, ride it on the wind.


      lliilillililliill ¤ The Endless Pursuit ¤

    9. Member meechelle's Avatar
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      09-02-2012 11:59 PM #9
      Quote Originally Posted by Getaway Car View Post
      Head work

      Curious to see some dyno results
      Me too! October if all goes smoothly with the final tune
      GSE - Granite State European
      flickr - ig: meechelle_k

      My GTI Build Thread - The Long & Winding Road MKV Version!

    10. Member arismkv's Avatar
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      09-03-2012 12:18 AM #10
      nice how much the vinyl cost you installed?

    11. Member Matt_Mkv's Avatar
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      09-03-2012 03:50 AM #11
      This is gonna be good
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    12. Member
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      09-03-2012 04:23 AM #12
      Quote Originally Posted by bryangb View Post
      Last I saw EJ website said it was under development for fsi, a week ago

    13. Member meechelle's Avatar
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      09-03-2012 10:07 AM #13
      Quote Originally Posted by RomanML320 View Post
      Last I saw EJ website said it was under development for fsi, a week ago
      This didn't make sense to me since EJ has had an FSI valve cover for a couple years so I checked out their website and lo and behold the valve cover is no longer listed under MKV products. Hmmm makes me think that they are redesigning it and that must be what you saw last week. Weird
      GSE - Granite State European
      flickr - ig: meechelle_k

      My GTI Build Thread - The Long & Winding Road MKV Version!

    14. Member meechelle's Avatar
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      09-03-2012 06:35 PM #14
      made some updates
      GSE - Granite State European
      flickr - ig: meechelle_k

      My GTI Build Thread - The Long & Winding Road MKV Version!

    15. Member OEM+ sluts's Avatar
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      09-03-2012 06:53 PM #15
      I like whats going on here
      there goes the neighborhood.

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    16. Member meechelle's Avatar
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      09-04-2012 03:54 PM #16
      Added the sad tale of my diff install just up from the bottom of the second post
      GSE - Granite State European
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      My GTI Build Thread - The Long & Winding Road MKV Version!

    17. Member
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      09-04-2012 04:19 PM #17
      500 whp. Im in for this.

    18. Member rhodri45's Avatar
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      09-04-2012 06:27 PM #18
      sub'd for final product. i've been looking into alot of this for my mk6, and your thread is just making me want to break my bank for it...
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      09-04-2012 07:10 PM #19

    20. Member meechelle's Avatar
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      09-04-2012 08:23 PM #20
      Quote Originally Posted by arismkv View Post
      nice how much the vinyl cost you installed?
      A friend did the vinyl - so hard to say. His cost for vinyl (he does this for a living) was ~$500 and not sure what the labor would cost on the regular
      GSE - Granite State European
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      My GTI Build Thread - The Long & Winding Road MKV Version!

    21. Member Ben from RI's Avatar
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      09-04-2012 09:27 PM #21
      I enjoy seeing people do headwork on our cars

      I would wrap the lower portion of the rear as well
      Build l Bag Riders l PVW 8/13

    22. Member thygreyt's Avatar
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      09-04-2012 09:42 PM #22
      nice build.

      i like that MKVs are getting to the point where more and better builds are happening.

    23. Member meechelle's Avatar
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      09-04-2012 09:54 PM #23
      Quote Originally Posted by Ben from RI View Post
      I enjoy seeing people do headwork on our cars

      I would wrap the lower portion of the rear as well
      The front bumper, lower rear valance and side skirts (I think I'm putting the Votex skirts that I have on) still need to be wrapped. Finishing up the vinyl is on hold until the mechanical work is finished.

      I'm planning on taking this to H2oi, most likely on the base tune, which might be a bit crazy but I've already had to pass on the pretty much the entire season.

      Got my fingers crossed that it all comes together in the next couple weeks
      GSE - Granite State European
      flickr - ig: meechelle_k

      My GTI Build Thread - The Long & Winding Road MKV Version!

    24. Member Ben from RI's Avatar
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      09-04-2012 09:58 PM #24
      very nice man, hope to see you there
      Build l Bag Riders l PVW 8/13

    25. Member kern417's Avatar
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      09-04-2012 10:08 PM #25
      sub'd
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      MK5 COMPLETE PARTOUT

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