So I am now going down the route of a 2L stroker. Already got myself the 06A 105 021 AR crankshaft removed from a Audi S3 8P 2L TFSI engine. Visiting the states for a wedding in July. Will be picking up a set of IE rods and 83mm IE Mahle pistons whilst I am there. Hate the dreaded import duty we have to pay on US shipped items.
Update 03/01/2016 K-Jet 16V 5 bar fuel pump assembly overhauled. Carrier bracket was zinc primed and powdercoated gloss black. Accumulator was zinc primed and painted gloss black. New reservoir fuel pump 'o' ring. Fuel line unions and fastenings wax coated for protection. Fitted under car. Front subframe zinc primed and powercoated gloss black, seem welded, polyurethane bushed and powercoated gloss black front lower control arms, overhauled power steering rack with polyurethane bush. Powercoated Vibratechnics rear engine and gearbox mounts. Front crossmember and radiator carrier zinc primed and powercoated gloss black, polyurethane bushed and powercoated Vibratechnics front engine mount. H&R 25mm front anti roll bar and polyurethane bushed drop links.
I know its a bit late now, but you dont need the accumulator once you ditch the k-jet setup. its no problem to leave it in mind, but if it pops in future it can be binned
@ John. Cheers! I kept it for originality really, as it was in great knick it was a shame to get rid of it. @ Pjuvis. Rebuilt 02A, Quaife LSD, Diesel fifth gear and fifth gear oil drip guide.
Update 10/01/2016 More work on rear axle as I finally managed to remove the Trilock locking wheel bolts that I had lost the key for; http://www.clubgti.com/showthread.p...ed!-How-do-I-remove-these-locking-wheel-bolts Removed the 16v rear discs, guards and stub axles. Fitting Polo GTi 6N stub axles and hubs as the bearings are far more suitable for the application. Had to carry out a thread insert repair using an M10 Time-Sert. I rate these better than traditional Heli-Coils. Running Spax RSX 'Venom' edition coilovers and a rear 28mm H&R anti roll bar.
Update 12/01/2016 Managed to track down a NOS Eibach front alloy strut brace. Will be fitting over the coming weekend
Update 28/02/16 Some rear axle work completed. Polo GTI 6N2 rear stub axles, bearing/hub assemblies (repacked with grease) and Brembo brake discs and power coated brake disc shields fitted. Torque figures Stub axle to trailing arm 60Nm Rear hub nut 175Nm Brake disc retaining screw 7Nm
Update 04/03/2016 Front Seat Ibiza Cupra R 305mm discs and refurbished Porsche 996 calipers fitted. Alloy 10mm PCD adapters fitted and M12 cap head screws torqued to 140Nm. Eibach front upper strut brace fitted. Close ups of the Vibratechnics engine/gearbox mounts.
Update 23/03/2016 Audi S2 25mm brake master cylinder overhauled using a Bigg Red seal kit. The circlip has no circlip plier holes so two had to be drilled. Freshly painted VHT metallic black.
Update 23/03/2016 Fitted rear EBC Red Stuff DP3680C pads. Re-greased caliper slide pins with correct silicon grease. Stainless steel HEL bleed nipples fitted. Caliper bolts torqued to 35Nm.
Very nice, meticulous work. I hope you're not oversizing the master cylinder as nothing good will come of it.
Update 28/03/2016 Steering column, steering UJ and Corrado hydraulic master cylinder pedal box fitted. Steering UJ rubber boot cleaned and treated with silicone paste. Started work rebuilding the G60 02A gear box that will be fitted with a all new bearings, synchro rings, a Quaife LSD, ARP crowngear fastenings, 02S oil drip pipe and a diesel 5th gear.
Update 03/04/2016 Input, output and Quaife LSD/final drive overhauled using new ARP fastenings, VAG bearings and synchro rings. Ready for shimming when I remember to bring my DTI home! Corrado 02a Cable Shifter overhauled using a B&M short shifter kit, new VAG bushings and a powder coated shell. The white centre shaft required modifying to get it to fit. New nylon fuel lines to be made next.
Update 16/04/2016 02A box now shimmed. Transmission cases ready to be bolted back together. Beach Buggy Turbo K418T K04 Hybrid finally turned up.
Update 17/04/2016 Heat exchanger box repaired. Removed the foam from the flaps and used 3M outdoor all-seasons woven tape in its place. Should stop the foam particles blowing through the vents now.
Update 18/04/2016 Transmission casing sealed and fastened together. Ready for the diesel 5th gears to be pressed on and the selector setup.
