MK5 Edition 30 #57 Track/Race Build

Discussion in 'Members Gallery' started by mat-mk3, Apr 8, 2016.

  1. mat-mk3

    mat-mk3 Administrator Admin

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    I know, I would have fitted them in any condition to be honest. The brembo's i fitted to the MK2 were peeling badly but it didnt matter as they worked fine still lol
     
  2. MUSHY 16V

    MUSHY 16V Moderator Moderator

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    cool nice to see all this hard work coming together
    I have to say i do like the look of the brakes wish i had that much clearance
     
  3. jamesa Forum Junkie

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  4. mat-mk3

    mat-mk3 Administrator Admin

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    Is there a special product i should be looking at James? I normally use a cherry non acid cleaner. I bought a 5l container of it a few years ago and it's just getting to the end of it lol
     
  5. mat-mk3

    mat-mk3 Administrator Admin

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    With the wiring out of the way. Prep work started for the cage install. This was going to be carried out by TSR who are not far from me. I have had a few chats with them and seen their work so confident that they can do the job.

    I wanted to remove as much as possible from the inside including unwanted brackets, within reason. I was not up for hacking huge chunks out of it as some of them add strength and it was more effort that it's worth. It was mainly the ones that got in the way and i knew i would catch my knee on if i was crawling around the inside so the ISOFIX and rear seat brackets etc went.

    I needed to remove the fuel tank for the welding but sadly this had half a tank of fuel in so spent a few ours bailing it out of the lift pump hole. I got as much as i could out and jacked it up to see what we could do.
    Firstly the exhaust. The car had a supersprint backbox (ugly thing that stuck out under the bumper) however the whole thing has been welded all the way back to the turbo! Some bodge job that is and it meant i needed to cut it somewhere.

    Access was an issue straight away. I couldnt get the car high enough to get a swing on anything, or even the angle grinder under the car. I have two pretty big jacks but it just wasnt enough and I have not even looked at removing the tank yet! There are loads of other jobs that need doing under it also like all the bushes, subframes, new exhaust etc. This job really needs a vehicle lift!

    I jumped on the internet to see what was around. Working space is not so much of an issue for me but storage space is. Any fixed lift is out the window due to the layout of my unit. I needed something moveable. A single post lift, on wheels!
    I managed to find a good company who I rang up and asked a few questions, number one being stability! Obviously its not going to be as good as a 4 post lift or even a two post lift but as long as you are sensible there should be no issue. So after justifying it to myself I purchased one and got it delivered next day!

    However I didnt expect it to arrive like this

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    It took a lot of assembly. About 3 hours in total and thank god I have a forklift. The whole thing weighs 750kg and I think most of that weight is in the centre column. They dont supply any way of lifting it, not even a hook at the top so we had to wrap a strap around it and hope for the best! Anyway, Finally I have access!

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    Its actually a lot more stable than I expected. We were hanging off it trying to get the exhaust and tank off and there was hardly any rock at all. Really impressed with it and it should make the rebuild sooo much easier! There is no limit to the jobs I can do now. Even just changing the brakes at a working height is amazing.
    You cannot see from the picture but there is a handle and a set of wheels behind the centre post that you can lift the frame off the ground and drag it out of the way. It's much like a pallet truck in it's operation but a lot more heavy duty.
     
    Last edited by a moderator: Sep 4, 2017
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  6. jamesa Forum Junkie

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  7. Deako Paid Member Paid Member

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    The brakes are already coated in Gtechniq ceramic. It's part of the service from Brake Caliper Refurbs.
     
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  8. MUSHY 16V

    MUSHY 16V Moderator Moderator

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    is this any good on polished alloy Luke ?
     
  9. mat-mk3

    mat-mk3 Administrator Admin

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    Ha! There you go James lol
     
  10. jamesa Forum Junkie

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    Me and my big mouth :p lol
     
  11. mat-mk3

    mat-mk3 Administrator Admin

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    I'm trying to get these updates in order as it's moving quite fast at the moment!

    I had a delivery to do in Bridgewater so thought it would be good to pop in to TSR while i was there and speak to them about a roll cage. I had been in e-mail contact with Rob already but just wanted to show my face and have a quick chat. Once i was there they showed me a couple of the cars they were building and i booked mine in there and then. Sadly with both TSR's and my workload, this turned out to be nearly 2 months before i managed to take the car down.

    While the car was away i still had plenty to be getting on with. When the car was on the lift I noticed that the rear axle was not in great condition and i needed to change all the bushes anyway so set about trying to find one that i could refurbish and build back up so all i would have to do is swap them over.

    However getting hold of a MK5 GTI rear axle is actually quite difficult! I spoke to several breakers who never got back to me, A couple on eBay that had seen better days and others that were in Scotland or London with no way of getting them to me. I tried one of these "find a part" websites in the end and within half an hour i had a breaker on the phone with a low mileage complete axle and he could ship it to me! The price was actually better than what i was quoted from other people and that didnt include shipping. It arrived a few days later and I expected it to be on a pallet wrapped up. However the driver said to me 6 parcels mate. The breakers had taken the whole thing apart to ship it to me, saved me doing it I suppose! lol

    Next, I needed some bushes. Funnily, at the same time as I was looking superpro released a new track/race kit for the MK5 Golf platform. You can see the press release for this at http://www.superpro.com.au/whats-new/media-a-press/item/309-superpro-upgrade-its-mk5-golf-kit
    Performance VW also did a feature on the kit which you can read here. http://www.superpro.com.au/images/whats-new/Mk5_Golf/SUPPVW0616_-_SuperPro_-_Golf_MK5-r.pdf

    I was already in contact with Henry Wright and Jamie Packham at Jtech performance parts as they are a Club GTI sponsor so I let them know what I wanted and they came back with a cracking price for it all. This included the alloy arms, front to rear bushes kit, front and rear ARBs etc. The whole 9 yards. They also offered lots of advice which was great. It wasnt just about the price, the service was excellent also. I ordered the kit from Henry and a few days later it turned up. Its beautiful! [:|]

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    However, the replacement rear beam was not so beautiful. In fact it was a mess of flaky paint, surface rust, road grime. The usual problems any rear subframe faces to be honest. I couldnt bolt on 1000s worth of bushes, alloy arms and roll bars to a rusty subframe could i? ;)

    Lets get cracking on the paint removal then. I could have got this professionally done but Im trying to save money at the moment as the spending is a bit out of control! I managed to pick up a sand blasting gun and some aluminium oxide shot for a good price from eBay. I have never done anything like this before so it was a bit of a learning curve to be honest but it came out pretty well I think.

    First problem, we needed to remove the old bushes, I found the best way (as suggested by Justin) was to hole saw the middle out and insert a hacksaw blade to take a nip out the side. This releases the pressure and you can knock it out with a socket. I had them all done in an hour!

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    The second problem was where the hell do I sand blast these? I have a big workshop but its pretty full, I cant just shoot metal filings everywhere and mixed with the rust it would have been a terrible mess. I also wanted to reuse the shot if possible as I know I was borderline if I had enough or not. So I needed a sealed container, big enough to take the subframe (arms removed). I know...

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    Yes, that is a pallet bin. We use it to tip waste into a large skip outside. We didnt care about the paint on the bin and its sealed around the sides, bottom and back so it just needs a lid and its good to go! The pallet as a shelf worked well also, it allowed the media to fall through to the bottom and I could just hoover it out.

    I spoke to one of my material suppliers to see if they had any scrap material. She had a scratched sheet of 3mm PETG that is perfect for what I needed so chucked it on my next delivery and it was like new to be honest. I managed to pick up a pair of blasting gloves from eBay also so I had the makings of a DIY blast cabinet for large items. A bit of hinge later and we have this contraption!

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    It worked really well, however I could have done with much more media for it. I put it through the 2nd time and it was less effective. It took twice as long to remove the paint but thats all I could do really without spending more money.
    Here are some comparisons of the parts.

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    Pretty good as you can see. The paint that is left on there is very strong so I left it on for added protection.
    Then its just a case of hanging them up and giving them a few coats with the black hammerite. I did the arms and a few other bits one night as it was very hot that week. 30+ in the workshop so had to be done at night to stop it from drying out so quick.

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    I spent a morning outside painting the larger parts as I couldnt fit it all on the forklift

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    They have been left for about 4 weeks now so I think thats enough time to let it go hard. I will be putting it all back together with the superpro kit soon. [:D]
     
    Last edited by a moderator: Sep 4, 2017
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  12. fasteddie

    fasteddie Banned

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    That's the way to do it! :thumbup:
     
  13. mat-mk3

    mat-mk3 Administrator Admin

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    One of the many jobs that needed doing was a dash making up. This was to house the following items:
    FIA cut-off switch

    Ultra gauge, really handy device to have. I had it installed on the MK2 and it was great.

    3 stack gauges, Oil Temp, Oil Pressure and boost!

    Im keeping the standard heater/blower setup (but removing aircon) so I needed to keep the factory controls. I could have moved them but it made sense to keep them in the same location as I can make a panel to fit into where the radio went.

    First I needed to get the shape of the cut-out, easy when you have the tools!

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    Next, CNC the panel out from 3mm diabond.

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    Trial fit, like a glove!

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    The gauges turned up, They look good.

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    I missed out sticking the panel in using fibreglass but its well stuck. Lastly, cover the whole in in carbon fibre wrap.

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    I went a little OTT

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    Thats another job out of the way :thumbup:
     
    Last edited by a moderator: Sep 4, 2017
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  14. mat-mk3

    mat-mk3 Administrator Admin

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    With the car still away getting the cage done i moved onto the brakes i bought from Luke. One new addition is alloy front hubs which i put a wanted advert out for. Who contacts me? Luke again lol
    I wanted to mock them up (or one anyway) because reading around, i was going to have problems with the carrier as the mounting point on the alloy hubs are thicker for added strength so longer bolts are needed from the S3 to go with the hubs. Some bolts were supplied with the brakes so it was a case of put them together and see what happens.

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    Here are the bolts supplied with the brakes. They have been replated so they look like new but sadly they are too short because of the alloy hub. This is even without a locking washer which they ideally need as the heads are quite small on them.

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    This is a factory S3 bolt that would be correct with the hub and standard carrier. It's the perfect length and has a locking washer built in. However this is not a standard carrier so the thread is a fine thread, not a coarse thread like the VWR brakes so that's a waste of money.

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    The two side by side.

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    The other problem is wheels. I was having trouble shifting the edition 30 alloys as they are rare and no one wants to pay money for them. I saw a set go for 100 more than I'm asking on ebay and they were in worse condition than mine. I was thinking about using them as track wheels until i fitted one over the brakes, well i tried to! I couldn't even bolt them up as the offset is all wrong so i either run a 5-10mm spacer or sell them. I don't want to run spacers on this car really so the best option is to sell them and purchase some proper wheels.

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    It's a shame as they do really compliment the brakes.

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    I look around on the internet and find a cracking deal on some pro race 1.2's. Doing research again these fit over the brakes fine with the correct offset and these are even the correct fitting from VWR. No spigot's, no spacers, nothing. Bolt straight on! They are also in the VWR anthracite grey which will look amazing once fitted. So i bought 10 of of them lol

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    [l] They look amazing behind these wheels.

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    Perfect amount of clearance, direct to hub fitment.

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    Purchased longer bolts and nord-lock washers for the fixing. I bought two sizes so have an option when i come to fit them.

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    While all this was going on i received a call from a friend of mine that a suspension set that i have been looking for just popped up on facebook. I had to stop what i was doing and look straight away as these just done come up 2nd hand. This set was removed from garage midnight's track project that never made it to the road. They were fitted and it was pushed around the workshop only so they are like new. I saved a load of money on these. They are KW clubsports so should be perfect for this car.

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    Oh, It's back! [:D]

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    Last edited by a moderator: Sep 4, 2017
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  15. Sirguydo

    Sirguydo Fastest milkman in the West Paid Member

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    Wrong model and colour lol better than queer green though , just lol

    Nice write up Matt looking good :clap:
     
  16. beetie

    beetie Forum Member

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    How much are you asking for the Pescara's? Mine have been painted black by the previous owner and need returning.
     
  17. mat-mk3

    mat-mk3 Administrator Admin

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    Haha, I really liked that colour! It looks great now in it's race livery.
    Wrong model? We shall see about that ;)

    Looking for about 550. They are on ebay at the moment but i'm getting offers of 300 and just laugh in their face lol
     
  18. Savagesam

    Savagesam Moderator Moderator

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    Very nice. I wish I had that kind of space and money to build a race car! :( lol
     
  19. babbe Forum Member

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    what offset will you be running. im running et 44 with 10mm spacer on my Mk5 ex cup car.

    in the Seat leon Wtcc manual it says that you shall run as wide as you have room for.
     
  20. mat-mk3

    mat-mk3 Administrator Admin

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    So do i! lol

    Space has been very tight the last few months. New machinery at work means i have had to move lots of things around but keep enough space for the car. The lift also takes up a fair space so need to find a home for that.
    I have no savings left :cry:

    I'm using ET45 also. I could go with a 10mm spacer at a later date (depending on clearance) but would look to change to studs/nuts at the same time once i have a bit more money to spend on it :thumbup:
     

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