Ibiza Cupra Sport rally project....CODENAME PROJECT: CHAV

if you have a look at the build thread on my MK3 you can pretty much see what we did.

1 - removed all ABS bits.
2 - bought and fitted a MK2 escort hydraulic GB cylinder kit and made up an ally bracket for it. This also has a bias valve inline to the rears
3 - Used the MK3 standard ABS master cylinder, each front wheel got an outlet each, the rears had a single that was plumbed straight thought the HB cylinder, then T'd off to the rear wheels.

This setup is ok, but you have to have the bias valve wound right off (minimum pressure to rear wheels) because it locks the rears a bit to keenly in the wet, although this improves once the front brakes have got some heat in the pads.

I'm going to rip it all apart over the summer and replace the brake pipes with braided lines all round, and I'm doing the MK4 rear caliper conversion as the MK3 are **** and seize up all the time.

Where abouts are you, you're welcome to come have a poke around the Golf if you're ever passing.

Cheers.

Noel

 

Envy, envy.
I desperately need a lightweight bonnet and hatch for my ongoing rally Ibiza, if anybody knows where I can get one
Jon

 

Have a look for a company called IZTeck cart seats (I think). I got a carbon bonnet from them for mine and I know they were making ABS / carbon products for other VAG models

 

thanks, will do
Jon

 

So, no real news on the engine / head front and won't be expecting them to be ready for another 3 or so weeks. In the meantime i've kept myself busy in the 'wrong seat' of another rally car of similar age. Now i know it's definitely not VAG, and probably against forum rules, but i figured that others seem to skirt around this minor detail so i thought i'd share a photo from last weekends Kick Start Rally of Derbyshire.

We suffered a puncture towards the end of the first half and dropped us a whole heap of time, but luckily we kept on going and bagged a class win and 26th overall. Had we not suffered a wimpy Dunlop failure, we would have been around 13th overall....next time we'll have 'em!

Below is a shot of me playing up in front of camera.....maybe to much Kick Start energy drink!!!!!!





And an arty one.....nice view to Chesterfield.





Photo credits to M & H Photography.

 

Progress!!!!!........Finally!!!!!!!!


I'm finally in a position to do a half decent update on what's been going on with my engine. We now have a freshly ground and polished crank sat waiting patiently with a very clean looking block and a load of KS and King racing bearings and thrust washers....all I need to do is pull my finger out and get into engine building mode....bit tricky when you have a 7 month old little boy rocketing around the house in one of those walker thingies.

As you might remember I bought an engine (ABF) as the original plan was to build up a spare and then do a direct swap over. This didn't really happen at all as when I was chatting to both the head guy and the engine machinist, they both said they'd like to see both heads and blocks respectively so they could choose the best ones for the job.....seemed to make sense to be fair.

The SEAT engine I bought was already cleaned and stripped a while back ready to rock and roll (pic's on page 2) so I set about removing my engine (and from now on we'll call that the VW engine as I don't think it's the original SEAT engine - Cams and lifters are wrong and it's got a 95 casting number on the head - car is a 98) from the car to get that stripped for transporting them all.

Whilst stripping this 'VW' engine, I discovered why I was having the issue with poor (almost none existent) oil pressure up in the head that was causing my tappet rattle that I couldn't trace - hence the engine work. When removing the filter/oil cooler housing from the block I noticed something sat in the oil gallery in the block.....it's (what i'm assuming to be) a pressure valve of some sort that has worked it's way loose from the alloy filter housing - probably due to engine vibration and general motorsport shaking! But at least I have tracked the cause of the pressure issue.







Obviously the housing will be cleaned before going back on a nice fresh engine!!!!! Should the pressure valve be put back in with Loctite???


Here is the 'VW' engine all cleaned ready to be coated in oil, wrapped in plastic and put away for a rainy day.....hopefully if all goes to plan with the build of the SEAT engine this rainy day may never come (famous last words!!)





A while ago I managed to find an ABF tubular euro spec exhaust manifold on German ebay that was cheap enough to warrant getting it shipped over here. Read a fair bit about these on this forum (cheers Toyotec) and they seem a cheap replacement for the cracked cast item.....whether I use this setup or even whether it fits remains to be seen, but as an experiment it is cheap enough to have a bash at. If all else fails I will use this as a template and go see a local fabricator and get a 4-2-1 manifold made and a proper exhaust. For phase one of the exhaust system this will do.





Picked this set up super cheap a few weeks back from GSF on their mega sale weekend - was too cheap not to buy, and in hindsight (what a wonderful thing that is!) I should have bought 2 sets.





OIL PUMPs!!!!!!!

Ok, so I've asked a few questions in the engine section of this forum regarding pumps and I've finally got to take some pics and measurements of my 2 pumps.

When I was first having the top end rattle issue with the 'VW' engine I removed the pump to have a look and found this lot in the gauze in the pickup





The large black bit is clearly some rubbery gasket sealant type stuff so no great mystery, but the red bits.....not so sure! They're a plastic of some sort and the large triangular piece on the right has a kind of tooth shape to it. It's definitely an engineered component that has obviously got chewed up somehow......any guesses what it was????


The pumps themselves......both got split and the gear backlash measured at above 0.2mm and quite a bit of noticeable wear and movement where the shaft goes through the body with the SEAT pump.....

Click for video












Fair bit of wear to the bottom faces of the pump (although these gaps were within wear limits) and the teeth obviously had some 'nicks' in them. Not surprising really as although these sit in oil - so should in theory be the most lubricated component in the engine - they are sat in essentially unfiltered oil with only the pickup gauze to protect them. In other words, any bit of grit that makes its way into the sump will at some point find its way through the pump and chew up the beautifully engineered teeth and mess with the alloy housing.

Been reading up on pumps in this article found on here......


http://www.clubgti.com/showthread.p...w-many-versions-FAQ-added-p2-Updated-p4/page2


....found it very informative (is Chris still on this forum?) and has opened up a few options with alternatives to the no longer available 051115105A VAG pump

Thank you to Gurds for pointing out the pump from the AEB engine is essentially the same but with a different pickup - easy fix that one!! So will try and hunt out one of those.

Been reading a fair bit about pumps and boring various folk with questions about part numbers etc, so hopefully i'll be able to track down a suitable replacement to my brace of worn out pumps.



In the meantime I will crack on with getting the as yet unseen crank and block assembled and i'm sure at some point this little beauty will make an appearance ...........

 

Been a while folks..........time for an orange update very soon.

 

Again at the risk of a hijack, my new cupra tarmac car is off to MOT tomorrow. Keep your thread coming, I promise I wont mention mine in here again
Jon

 

ha ha.....not like you to hijack my thread!!!! Not a problem mate, in fact you will star (kind of!) in an upcoming update!!!!

 

LOL, hope its not Croft pictures...
Jon

 

No no.....nothing incriminating, just a mention.

 

Just had a quick glance through my poxy 3 page build and I've realised I have missed quite a bit of 'stuff' from before I made the engine make funny noises. Luckily since the engine rebuild started I have pretty much stripped the front end entirely so whatever had been done in the past is probably now being tarted up a bit more, made better, or neater, or stronger.....so fear no my minuscule readership, we shall catch up over the next few updates.

First up - we might as well start with the anchors. On the last event (2015 Moonbeam rally) the brakes were starting to show signs of grabbing and all was not well behind the MO's. I decided to fully refurb the calipers and make good what the VAG parts bin provided us with....Lucas 54 'A.K.A' G60 calipers (among others).

I know there are folk out there that do track days and racing and this, that and the other, that will ask why I've gone to such effort and not bought some big multi pot calipers from Wilwood or Brembo or whoever.....the truth is, when my setup was working, it worked amazingly well and had superb pedal feel and bite, so why spend silly money if I can massage these back into life? Yes my setup got hot, yes the pads destroyed the Black diamond discs and sent sparks flying everywhere, but they work.....and work well to be fair.





First up was removing the seized piston. A bit of heat was required and even removing the seized pipe wasn't without it's excitement!!!! Heat again came in to play and I managed to make the rubber/metal connection explode which made me jump a little and make me feel glad I had my safety specs on for once!!!!! Hot brake fluid everywhere and a ringing in my ears - but the pipe was out.

The piston was helped out with some compressed air and as you can see from the pic's, there is clear evidence why the brakes felt past their best. Near side caliper piston was corroded but the O/S one was actually fine, but I will be replacing all seals and pistons as a matter of course to establish a good base.

Once stripped using a bit of nasty chemical assistance, I made up a wooden bung to replace the piston and brought the calipers in to work for an appointment with the media blast cabinet and then a lick or two of high temperature enamel








I know....I KNOW!!!!!!!!!! I am a TART!!!!!!!

All will be made clearer once all of the other updates are posted..... but I like the colour and it was left over from another project. If i'd had red, I would have probably used that, but the orange looks great in contrast to the Kiwi so for now lets just pretend I'm not a tart into detailing bits on my rally car that will eventually get covered in mud and pad dust and i'm doing it so the end build will be spot on..........don't judge me!!!!!!!!

 

Hahah! Orange.

Did you find an oil pump? I bought mine from TPS which means VW/Seat still stock it.

Gurds

 

Hi Gurds.

Yes it is rather ORANGE!!!!!.......but you ain't seen nothing yet (as the song goes!!!!)

Oil Pump - no I still have yet to source a proper one. I did buy a KS one off ebay but it was shocking (post with pics yet to come) quality considering that KS make nice stuff. Sent it back after some arguing from the seller but when I quoted tolerances he soon shut up and issued a refund.

Is the one you bought a proper VAG one? Must mean there is a stash somewhere.

 

ABF oil pumps assemblies (051115105A) have been obsolete since 01/02/2013. Although I have not had a reason to do so yet, I understand the main pump is similar to the item 058115105C, used in B5 Passat/A4 engines 20vT and 20v engines, codes APU, ADR and AEB.
Make sure to take care of the oil surge baffle as it is brittle at best. Very important item.

 

Yep, what I found too and I bought the pump for an AEB. Cupra_Rally said that that helped.

 

Yes, get it direct from TPS or VW. They were not obsolete as not many people buying replacements for them I guess. Not cheap though.

 

Hopefully my steel baffled sump will sort that side of things out. But yes they are brittle.....broke one but do have one that remained intact.

 

Go on then....shock me..........i'm sitting down.

 

Around 200 from memory.