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Sav's 1991 Golf Mk2 GTI 16v - Update - It lives - 10/02/2018

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sava001006 Part of things Posts: 12	Sav's 1991 Golf Mk2 GTI 16v - Update - It lives - 10/02/2018 sava001006 @sava001006
	Sept 10, 2015 8:26:37 GMT Select Post Deselect Post Link to Post Back to Top
	I will copy most of this off another forum but a little back ground, the idea was to but a old sport car mx5, golf gti's etc the do a mini restoration then take it to the 'ring in Germany. so here is the story hi all, i am new to the forum and new to golf ownership but i have been into classic vw's for a while a few years back i restored a 1973 beetle from this 19/04/2011 by Savage_photography, on Flickr to this B&Q (1) by Savage_photography, on Flickr as you can see I'm not afraid to get stuck in, after fully restoring the beetle i can weld rather good spray wire etc, all done myself, right this isnt a beetle forum so i have just got myself a little project its a 1991 Gti 16v in Royal blue (thats what the paint code says it is) its currently got not MOT as it does need some tlc. looking at it, its needs - a good service belts job lot (it has come with FSH - so it has been looked after) - a little welding round the windscreen and some and the passenger side rear arch, nothing major welding so far. - a new passenger front wing - a tailgate as that has many holes in it - does need a new passenger door but got one of those just needs painting and fitting - new spot lamp on the drivers side as it is cracked - 4 new tyre's as these are snow tyre's (what do people run i normally go for T1R's? - drive side window motor i'm sure after digging around when i can free the workshop up i will have many thing needed but generally its not it too bad nick i have order full service kit and a toad alarm as I've got one in the beetle and they brilliant right anyway thats enough blabber here are some photos when i just got it, and before i gave it a quick wash Just Got Home by Savage_photography, on Flickr Just Got Home by Savage_photography, on Flickr Just Got Home by Savage_photography, on Flickr Just Got Home by Savage_photography, on Flickr Just Got Home by Savage_photography, on Flickr Didn't really get chance to do much today, as i spent most of the time getting the beetle ready for the summer, but first think first was to remove the battery, the clamp was well rusty but after the used of a hammer its out, next up was the starter motor as on of the connections on the solenoid had corroded away. 20150322_172207 by Savage_photography, on Flickr doesnt look too rusty just needs a good clean 20150322_172216 by Savage_photography, on Flickr this needs a new one, but after looking round the mountain of vw parts i have i noticed a starter motor which had broke had the same solinoid on it, (gave it a lick of paint as i hate putting rusty parts and screws back in) 20150322_205112 by Savage_photography, on Flickr will try to fit this tomorrow along with the new battery see it if can start under its own steam managed to start and strip the car, every bolt that need to be undone see to be the rustiest bolts on the damn car so progress wasn't the quickest, I've also got it say on axle stands so i can see whats what underneath, first inspections of the wheel arches are there's a little rust, but the discs and pads are like new. then the dreaded rust after stripping the front bumper off front wings rear bumper and some of the interior I've found some rot that needs looking at, any way here are the photos passenger inner wing Strip down by Savage_photography, on Flickr Strip down by Savage_photography, on Flickr the drivers side inner wing isn't too bad at all, will just put a small piece in there Strip down by Savage_photography, on Flickr then the rear of the car, maybe i will put a pannel in here as it it might start looking like a patchwork quilt Strip down by Savage_photography, on Flickr Strip down by Savage_photography, on Flickr Strip down by Savage_photography, on Flickr the rear bumper support or what ever you call it is well gone, are you able to get them or it is a new bumper? Strip down by Savage_photography, on Flickr and finally got round to the interior and managed to find a hole under the rear bench - this is only small so it a 2 minute job really Strip down by Savage_photography, on Flickr and after cleaning the workshop up i left the car something like this Strip down by Savage_photography, on Flickr Nothing major to update but a little process, i'm still stripping down the interior. but today i managed to change the cam belt which seem to take more doing that it should be its done now, I've also started to weld up some bits on the car i naturally started with the fiddly bit first :roll: :roll: :roll: and i manged to sort it I may add it doesn't look massively pretty and yes it does resemble pigeon poo but its the best part of 2 years since i've picked up a welder and i'm a little rust at best (well that's my excuse :lol:) Strip down and weld by Savage_photography, on Flickr also i've just put in a order for some weld in panels as i don't fancy fabricating the arches as there shot update time got some rear arches delivered so cut the rear arches to bits and welded them all back up didn't get load of photos but you get the idea then grind them back and then blag over with primer, the guy who is spraying the car is going to fill the arches to make em look flawless more update the sill I ordered has eventually come some managed to weld that in, had to do a bit of fabbing of the bottom of the A pillar first and then on with the rest of the sill also with replacing the rear arch I had to tie that in to the sill, which went together rather nice one this had been done, it was the inner arch section and the top of the inner wing and once all that was done I spray over some primer to stop the rust for a little bit once that was all done I but on the new wings, to see how they fit as they are not genuine parts I haven't fully bolted them up but the shut lines are rather good, not perfect but I can sort that later, any way this is how I left it not got much left to do just a couple of small parts on the back of the car and then it is done and ready for paint, I'm just having it blown over in the same colour otherwise I would end up taking the engine and everything out so this is the easier/cheaper way got pleanty of updates and big ones imo first of all welded up the rear valance, this took some doing but after hitting and swearing it fit once that was done it was onto the prep of the car, this was to help the body shop as he is a mate and turning it round in next to no time and then it was into the body shop and every so often i keep popping in, and the guy whos painting has been sending the pics across then got a message say that the paint was going on ^ that was the gun finish and today i go a message saying it was ready to pick up :brian: :brian: :brian: i cant wait, also managed to re tim the headliner today which also has to be glued back together which was real fun :roll: :roll: as the eagle eyed will notice not all the holes are cut out, but i will sort this when i put the headlining back in hopefully picking the golf up within the next couple of days and then i can start bolting things together having not updated this is a while as I've been silly busy, I wanted to get my car to DC15 and the week after Trax at Silverstone, not that important deadline but its best to work to something, but here the story is... just got the golf back from the body shop and I generally didn't know which bit to start on first. the played with some hammers, start putting seats lights coil over on it then started putting more and more parts on the car also while under the car putting the fuel tank on I spotted that the back box had a hole in it, so I picked up a stainless steel one - surprising the old one came off rather easy which was a bonus this is where the photos run dry, as I just started putting the car back together, the hardest bit was the sunroof which was a epic challage and one word of advice is to take you time its easy to mess things up any way I got the car done for DC15 and the week after I got some photos on the disused part of Silverstone track so now it is all on the road, legal etc there were some bits that needed doing, the first been the sump seeped out from round the gasket so a quick replacement sorted that out. There also is a wine which I do believe is the power steering pump, and I think that this is on its way out because the rack leak - it was the 2 pipe on the rack (steel one) and you cant get them but mk3 racks have the same pipes so I got a cheap ass rack and raided it for bits. as for the pump I'm going to look in getting one soon. There's a few bits and bobs that need changing with the car but it drives great, having not drove one before getting this I didn't know what to expect, its brill not the fastest thing on the road but in terms of smiles per gallon it tops the beetle (almost) I have now booked the car in for a track day at Cadwell :brian: but before that there are a few bits that need doing on the car, the first on is the steam seals I wanted to run the car to see if the smoke was the steam seals and not just that it hasn't ran, and as luck has it, its the steam seals. so first thing was to jet wash the engine as it was oily and generally a mess 20150808_160156 by Josh Savage, on Flickr used a good de greaser and the pressure washer. then it was on to taking the head off, took some time as the exhaust manifold bolt (the one you cant see) was solid so took forever to get it out 20150809_180617 by Josh Savage, on Flickr one photo I got was this one. - stripped everything down got the steam seals out of the head and while there I checked the valve guides and they have gone, so ive phoned up the local machine shop and they are sorting it for me. while the heads getting new valve guides and what not I have got some 280mm brakes off the G60 to go on, here is the before photo 20150811_184834 by Josh Savage, on Flickr then the old discs at the side of the new ones 20150811_194856 by Josh Savage, on Flickr brilliant so on with the carriers, then the pads. and just my luck the wrong bad :frustration: 20150811_204845 by Josh Savage, on Flickr so off to get them changed for some other ones photos of the brakes, I used the old pads just so it look complete Brakes by Josh Savage, on Flickr Brakes by Josh Savage, on Flickr More updates, the other side brakes 20150813_194512 by Josh Savage, on Flickr 20150813_194930 by Josh Savage, on Flickr and on with the wheel to make sure my brakes fit 20150813_195913 by Josh Savage, on Flickr so, 280mm brakes DO fit under BBS RA's with 5mm spacers, the pads aren't brand new but don't have a lot of wear on them also the head has come back after having repairs, so its looking all well now 20150813_200757 by Josh Savage, on Flickr Well did the track day and what a buzz the care was great and didnt skip a beat, oil temp never got much over 106c and the water was good too, I'm hardly the stig but it was a great day, even managed to get some tuition so i knew what i was doing.. ish here a few photos from the photographer that was there Cadwell Park 240815 by Josh Savage, on Flickr Cadwell Park 240815 by Josh Savage, on Flickr Cadwell Park 240815 by Josh Savage, on Flickr i have plenty if you fancya look click www.flickr.com/photos/joshsav/albums/72157651472191932 got a video of the last session i went on too, i think this was the fastest but my lines on one or two of the corners are a bit off the power steering has had its issues since I've got the car and I've eventually got a new pump so off with the old and on with the new Power steering pump by Josh Savage, on Flickr Power steering pump by Josh Savage, on Flickr which fixed the problem so town driving is now a doddle in other new on the way back home from the pub the car decided to break down, so a quick call to dad and he got my battery off the beetle and we fitted it to the golf to get me home, about a mile if that, turns out the altinator has given up, lets hope this is the last thing on the golf ready for Germany as that's only 27 days away now :party!: :party!:
	Last Edit: Feb 10, 2018 18:16:43 GMT by sava001006

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darrenh Posted hell of a lot Posts: 6,636	Sav's 1991 Golf Mk2 GTI 16v - Update - It lives - 10/02/2018 darrenh @darrenh
	Sept 10, 2015 10:44:06 GMT Select Post Deselect Post Link to Post Back to Top
	tob job on this restoration so did you end up changing the paint colour back to what it should be, or is it the same colour just the camera / sunlight combo lying ?
	1989 Astra Merit estate 1991 Astra GTE 16v group A build 1982 land rover 88 sw

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sava001006 Part of things Posts: 12	Sav's 1991 Golf Mk2 GTI 16v - Update - It lives - 10/02/2018 sava001006 @sava001006
	Sept 10, 2015 11:14:36 GMT Select Post Deselect Post Link to Post Back to Top
	cheers, its the same colour, but when I got it the paint was in a bad way (scratched and faded) its Royal Blue metallic, still need to polish it and wax it just not had time between driving it and work hopefully I will clean if before Germany


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The Jackeria Posted a lot Posts: 1,837	Sav's 1991 Golf Mk2 GTI 16v - Update - It lives - 10/02/2018 The Jackeria @jackeria11
	Sept 14, 2015 4:32:26 GMT Select Post Deselect Post Link to Post Back to Top
	Well done so far! looks great!


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sava001006 Part of things Posts: 12	Sav's 1991 Golf Mk2 GTI 16v - Update - It lives - 10/02/2018 sava001006 @sava001006
	Sept 16, 2015 19:02:30 GMT Select Post Deselect Post Link to Post Back to Top
	Sept 14, 2015 4:32:26 GMT The Jackeria said: Well done so far! looks great! Cheers bud


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sava001006 Part of things Posts: 12	Sav's 1991 Golf Mk2 GTI 16v - Update - It lives - 10/02/2018 sava001006 @sava001006
	Sept 16, 2015 19:03:42 GMT Select Post Deselect Post Link to Post Back to Top
	so this happened on Sunday New wheels by Josh Savage, on Flickr New wheels by Josh Savage, on Flickr there is a bit of rubbing on the front so i think i will have to go for a 195 45 15
	Last Edit: Sept 16, 2015 19:05:21 GMT by sava001006

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sava001006 Part of things Posts: 12	Sav's 1991 Golf Mk2 GTI 16v - Update - It lives - 10/02/2018 sava001006 @sava001006
	Sept 21, 2015 8:21:18 GMT Select Post Deselect Post Link to Post Back to Top
	had a good clean and polish at the weekend, still need to get better tyres and it now has a issue with the HU which I need to sort out but managed to get some snaps Cleaning by Josh Savage, on Flickr Cleaning by Josh Savage, on Flickr I noticed the bumper after the photo Cleaning by Josh Savage, on Flickr Cleaning by Josh Savage, on Flickr Cleaning by Josh Savage, on Flickr


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sava001006 Part of things Posts: 12	Sav's 1991 Golf Mk2 GTI 16v - Update - It lives - 10/02/2018 sava001006 @sava001006
	Oct 1, 2017 11:47:19 GMT Select Post Deselect Post Link to Post Back to Top
	Well to resurect a old thread I best update this as its been a MAD few years since so with a little bit of copy and paste, enjoy right haven't updated this is a while, i did manage to get the car completely sorted on the Thursday it was just a ignition switch that was draining all the battery, so i did get it fixed in time for the ring. after driving 1500 miles to Nurburg round the ring and the roads round there the car was faultless even up with the M3's S3's and a 4.4 V8 Volvo it gave them a good battle in the corners, anyway I did make a short video about the trip, took hours of video so might look at the other bits I recorded. and for those wondering how fast you can get on the autobahn in a standard 16v here is the video and one last video which was the quickest lap i did 12:35 which isnt quick but i did have fun doing it also got a couple of photos round the ring so yeah Germany is brilliant one on the list to do next year. that leaves what for the car now? it was bought and built to go the ring and that's it. but in the blood sweat and tears that have gone into it i cant quite sell it yet, so the basic plan is to do more track days, with a few tweeks to the car, ARB's possible cams and just bits to improve its track capabilities. so with that ive got some G60's at the powder coaters and i just got these to fit on it they are NS-2R's with a 120 compound cant wait to try them, the first outing on them is in 2 weeks at Blyton park (1st Nov) Up date time, it track time having the tyres already bought I got a spare set of g60s I had laying about powder coated in metallic grey so that on the track they wouldn't show too much brake dust, I got them done at dragon powder coating who has done a lot of work for me and manages to turn bits round in great time. I also asked if he could put a clear lacquer on them as this would give them extra protection with them been wheels. any way here a pic Track prep by Josh Savage, on Flickr I also gave the car a quick once over make sure everything is how it should be and after a quick wash too Track prep by Josh Savage, on Flickr Track prep by Josh Savage, on Flickr then its a quick fill up and ready for tomorrow Sunday - its time to head to the track, I set off nice and early to get a good spot and meet up with James (cope on here) having got 10 mins away James already messaged me saying he was there, I thought I got up early to get to the track. anyway parked up set pressures and moaned about the weather, any way a quick briefing telling us the usual's of flag colours and just be safe, no racing etc Blyton Park 1st Nov 15 by Josh Savage, on Flickr then the wait till the track cleared which was annoying but to pass time I walked the track having never seen it myself Blyton Park 1st Nov 15 by Josh Savage, on Flickr this was took at Lancaster but after the long wait we did get back on track, got some video too on this video I took a friend out who come to see us all there I the tyres I was using were brilliant I never found the limit of the tyres - abide i'm not the quickest driver out there. got the next track day at Cadwell on 21st so not too long wait this track day business is addictive. not much of a update but on Saturday I was at Cadwell again not got any photos up but they will come soon, the day started wet and been on the ns2rs wasn't as bad as I thought I was still lapping quicker in the wet with them than in the dry with t1rs. through the day the track dried up and got some real pace going see the video rather happy with the pace last time on t1rs - 2:24 on the nankangs - 2:06 I know its not fast compared to some but happy with progress lets hope I get faster (before someone comments about timing on a track day its gps and I don't look at it till I get home so I'm never trying to beat my last time) I was flying round Chris curve and then was a terrible rumble from the NSR so a quick pull into the pits, jack up and the wheel bearing is past it, also while checking the wheel bolt torques, popping the hub caps off the g60s and the wheel bolt fell out on the front, sheared at the hub its 2 weeks before i'm back on the track and I've got a few bits to-do - sort the rear bearings out (got new discs and pads to go on as well) - extract the bolt that snapped (got some new studs all round) - got a g60 front arb and poly bushes to go on - head shield rattles like you wouldn't believe so I need to bend that back or something - go a lower front brace to go on (picked it up cheap) - change the gearbox oil (never been don't and it wouldn't hurt) so got a few things to-do before it is next out in 2 weeks time lets hope I can get it all done ready for the track I will grab some photos when the parts I need turn up... I promise managed to upload some photos from last weekend Cadwell Park 21.11.15 by Josh Savage, on Flickr Cadwell Park 21.11.15 by Josh Savage, on Flickr Cadwell Park 21.11.15 by Josh Savage, on Flickr the above shot sort of shows how wet it was in other news the parts have turned up so that I can sort the rear bearings out, and just got to create a mounting point for the harnesses at the tunnel side. so hopefully should be back on 4 wheels again soon


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sava001006 Part of things Posts: 12	Sav's 1991 Golf Mk2 GTI 16v - Update - It lives - 10/02/2018 sava001006 @sava001006
	Oct 1, 2017 11:52:39 GMT Select Post Deselect Post Link to Post Back to Top
	been a little while since I updated this, someone contacted me on instagram saying they had some photos of my car, they then sent me these from Cadwell which I was really happy with 081215 Cadwell Park by Josh Savage, on Flickr 081215 Cadwell Park by Josh Savage, on Flickr 081215 Cadwell Park by Josh Savage, on Flickr 081215 Cadwell Park by Josh Savage, on Flickr also uploaded another video from the day when it was dry this was a 2:07 with my optimum been 2:04 so I still can go faster (again I don't look at my times till I'm home) Like you cannot get enough track days I can see. We are hoping this year to have quite a few track days that you joining and share the spirit with the rest of the Club GTI guys. So far we can confirm Brands Hatch on February the 19th, Donington on the 12th of March, Curborough on May 30th and August 29th. ive currently got a couple booked, - 3rd January - Mallory park (never done this one but looks quick) - 30th January(I think) - Donnington (again new track to me) I may look into Curborough as that's not too far away. and track days are mighty addictive its great to go there and drive the car how it should be then tootle home. roll on summer *She looks lovely, my right foot is twitch and tapping wanting a paint job like that to wash on mine!* I then gave it a much needed clean and used my swissvax to give it protection. Wax time by Josh Savage, on Flickr Wax time by Josh Savage, on Flickr Wax time by Josh Savage, on Flickr Update time, few little updates to the car, the first on been bonnet struts - simple fix was just a swap of a few bolts makes working under the bonnet miles easier 20160102_135349 by Josh Savage, on Flickr the other was to change the bulbs on the switches and heater controls as there were dim and the heater one had broken. I've also got the clocks leds to go in but haven't had chance yet Led conversion by Josh Savage, on Flickr also been working on refurbing the RM's ive got sat about, nothing major just a strip polish and clean really, 120 bolts are annoying mind found that to get the bolts shining again a bit of Cilit bang help out (the orange one) 20151227_203032 by Josh Savage, on Flickr 20151226_134535 by Josh Savage, on Flickr it was then onto the prep ready for Mallory Park, first up was the change on tyres onto the NS-2Rs Santa got me some lovely wheel bags which keep them nice and also show which go on which corners 20160102_124345 by Josh Savage, on Flickr then while I was out with the car I put the 2 camera mounts on 20160102_151016 by Josh Savage, on Flickr 20160102_150956 by Josh Savage, on Flickr onto Mallory Park, up early and trek down there 1hr 45mins from my house, having never been to Mallory I knew you had to cross the track but still managed to get lost, managing to-do a lap the wrong way round before find where I was going, one there location somewhere to get a brew as it was cold and damp. the usual signing on and surprisingly no sound check just one drive by type, on the signing lap someone in a hire MX5 lost the roof an spun out on the next corner today was going to be fun. once the pit lane was open I always give it 15mins for the heros to calm down, after that was my first run, I managed 2 full laps before red flag and someone was spun out got a video too, not that quick but a 1:23 but taking it steady as it was very wet for the next 3-4 times out on track I the red flag kept coming up it got annoying but it is what it is, after dinner I think most calmed down as I managed a good couple of runs and my favour was the last of the day as the standing water was leaving the track and at one point there was only 4 or so cars out on track and we all were a similar pace so no one was over taking could really concentrate on getting a good lines I started to get quicker and by the end of the day I managed a 1:18 which I was happy with its a long video as its the whole session got some photos while I was there which really show how wet it was Mallory Park 03.01.16 by Josh Savage, on Flickr Mallory Park 03.01.16 by Josh Savage, on Flickr Mallory Park 03.01.16 by Josh Savage, on Flickr the car was rather well behaved and the only issue was water on the belts, which I'm going to look at and see if the belts too tight or not. And looking at the front one of the spot lights is cracked now so need fixing small update, I've had chance to have a look round the car after the track day, firstly I've notice that one of the spot lights had picked up a stone and cracked the lens, I don't use the genuine ones I rather like the cross hair ones so there only £20 a set so no big deal real. I then looked at the alternator belt to see what's up with the squeal coming from it and the belt was just off snapping, I forgot to get a photo of this but as a temporary fix I used a beetle fan belt as there 10x900 (the belt I needed was 10x950) and it just fits so I've order a 10x925 as it will fit better imo next up was to take the wheels off check the brakes make sure pads and discs are okay, as I went to undo the one of the nuts for some reason it rounded off, so I bought some better quality one as I don't want wheels coming off on the track 20160110_124347 by Josh Savage, on Flickr and the next bit to do was to fit new rear ARB which required some welding of the brackets bit sorted all that out 20160110_143534 by Josh Savage, on Flickr I have tested it but on the roads round me you cant push the car to tell so when I'm at the track on 31st (donnington park) got some more updates first of all I made a purchase of these, its a bit of a long term plan but they came cheap so I snapped them up, going to be running with 1.8t injectors, some form of uprated cam (not too harsh, I still want to drive it, on the road) and a manifold, all looked after by emerald ECU, 20160125_213513 by Josh Savage, on Flickr with looking at doing this I booked on for a rolling road to get some base figures, the RR that I went to was more for race cars that the old golf as it shows WHP only nothing at the fly 20160130_170928 by Josh Savage, on Flickr it pulled 102hp and 101 ft/lb see the video from the session here that aside its track time this time it was Donnington short the usual prep of the car, my tyre choices aren't that good as I've go t1rs and ns2rs now I've had the t1rs in the wet at the ring and the grip was terrible in the wet so it was the choice of ns2rs as I knew how these handled from Mallory so car all prepped up it was time to head out to the track its around 1hr or so from Doncaster so at 6am on a Sunday there isn't any traffic, first of all I found the garage with my name on it and opened up and un packed, then went looking for signing on, now I don't know if it was me tired or not signed very well it took me forever to find out where I was meant to go (first time with the TDO and first time at donnington) 20160131_073908 by Josh Savage, on Flickr I went along with a friend who was taking his MK4 golf out for the first time, after the briefing and signting laps it was time to go out, after a few laps getting to know the track it was going well, we went out in my friends golf for the last session before dinner and a few laps in a full spin off coming into Craner curves (lift off oversteer) didn't hit anything but managed the throw mud everywhere 20160131_122350 by Josh Savage, on Flickr 20160131_122616 by Josh Savage, on Flickr my golf was enjoying its self on the track, not the quickest as the tyres aren't exactly best for wet managed to get some good laps in managing a 1:58 with the optimal been 1:56 a video of my fastest session and got some photos from the day too Donnington Park 31-01-16 by Josh Savage, on Flickr Donnington Park 31-01-16 by Josh Savage, on Flickr Update time again with Oulton Park just around the corner, my brake discs are badly warped, vibrating the whole of the car now so I needed some new discs and to fit them within a week so a swift purchase of some new drilled and grooved discs and they came the next day 20160203_192850 by Josh Savage, on Flickr didn't take much fitting but at least I don't have wonky discs anymore 2016-02-08_10-02-21 by Josh Savage, on Flickr on to the race track I remember some seat this time so I'm not eating and staying in the car most of the day, I remembered tools, fluid, food etc. Was quite well equip or so I thought, not long after setting up a artic lorry turned up which I thought was a delivery turned up, nope I was wrong it had a Ferrari race car turned up (458?) which was stunning 20160206_114626 by Josh Savage, on Flickr and this was in the garage at side of it 20160206_114849 by Josh Savage, on Flickr mine didn't look the same in the garage though 20160206_113809 by Josh Savage, on Flickr the day went well, I wasn't the quickest guy as I'm terrible in the wet, after the first couple of times out on the track and I had very little grip after a lap or so, so a look in the pit at the tyre pressures that was silly high at 37 psi in the front and 35 psi in the rear, these were set at 30 all round so I dropped the pressure to 25 front 27 rear and went back out, it felt a mile better grip wise so was rather happy with that, any way the video from the day also grabbed some photos XSP_0866 by Josh Savage, on Flickr XSP_0597 by Josh Savage, on Flickr the day come to the end and started to pack up ready to go home, now it was 109miles away from home so a nice steady cruise through wood head pass and m1/m18 I noticed the battery light cam on, so knowing that this meant the alternator was having fits I turned off radio charger heaters. This was 20 miles from my house I managed another 10 miles before I broke down, and this is my view 20160206_192011 by Josh Savage, on Flickr after a call for someone to get me a battery I managed to limp it all the way home, so parts list needed - windscreen - alternator - spot light (yes still not got these) I managed to get a windscreen alternator and a rear wiper motor off Malc which was handy so hopfully it will be full fixed before too long right with a currently broken car and Blyton was just around the corner it was time to fix it, so first was the windscreen simple job really ive don't many screens before so it was just a cae of pushing the screen from the inside with my feet easing it gently out (its already broken so there was no point cutting the rubber as this is still in good condition, so out the windscreen comes) 20160214_172441 by Josh Savage, on Flickr and the new one goes in thanks to Malc next up was the alternator, and in the breakdown I never really checked the alternator I just presumed dead (I was at the side of the motorway in the wet I wasn't going to start fixing the car) I failed to notice the lack of alternator belt, I know I know so simple fix as I always like to have spares such as this I had a 10x925 belt in the workshop its 25mm shorter as I've found that the 950 seem too long IMO so after a cursing that I have to take the power steering belt and pulley off I fixed it all up and ran it for a little while and it was fixed simples now onto the track days, the usual inspection and camera brackets were put in place, even managed to give the old girl a wax which was nice as I was 2 track days in the wet without a real clean 20160220_170044 by Josh Savage, on Flickr 20160220_154114 by Josh Savage, on Flickr onto the day, set of nice and early get a good spot that isn't miles away from the track, did the usual check levels, moan about the weather and sign on. just after the briefing I lined up ready for the sighting laps pulled forward to make room and the TDO pulled me over and mentioned I had a fluid leak and dump some oil on the starting area, so spun the car around and back to the pits, without boring you on details after a couple of hours on trail and error, I narrowed the leak down to the gearbox side of the sump, it a last resort I tried to tighten the bolts up just a little bit see if that held, moving it onto fresh tarmac and then letting the car warm up to see if there was any leaks, BINGO no leaks so onto the track, its was around 11am so only lost a could of hours. other than that the day went well, the oil got rather hot at 104c after 20 mins driving so that governed how long each session was. doing really well all day, then if by magic the car broke again. picking up pace as the track dried out a little bit I was getting quicker and then after a couple of corners a vibration come through the car when turning left, pulled back into the pits made sure nothing was a miss (I check wheel bolts before every stint) after letting cool down I went out for one last stint it still made a funny noise and me been me went out just for one last stint. this was the best outing of the day managing a 1:30 lap which is 2 seconds quicker than the last time I was there so I was really pleased with that anyway I've got a video from the day also got some photo the first one is on of my favourites as I was with lee (silver more door v6 4motion) and cope (small bumper 8v) received_10156524911690006 by Josh Savage, on Flickr received_10156524907115006 by Josh Savage, on Flickr ^^ so close to lifting a wheel so I now have a list of bits to sort - spot lights still - rear wiper motor - noise from front left - possible oil cooler - going to take sump off and re seal maybe a windage tray and DIY baffels with no more track days booked yet there is not rush and with 2 lots of ring trips to pay for it might be tight old month As I keep forgetting to update this its about time I did first of all last time I was at the track was getting an oil leak which I thought it either could be crank oil seal or the sump gasket failing (quite hard to tell when there is oil everywhere under the car) so plan of action was to change the crank oil seal and sort the sump gasket out - and put a windage tray in there. so before starting to remove the gear box I jet washed the engine so at least it was a little cleaner 20160312_141142 by Josh Savage, on Flickr after it had dried it was strip down time, because i was fitting a external oil cooler and a new factory cooler too as I think this is weeping too, I decided to remove the radiator and drain the system when i took the radiator off i notice it was rotten in the corner 20160319_122030 by Josh Savage, on Flickr so i order a aluminium one to help with cooling along with a slime line fan again to aid cooling on the track 20160315_182117 by Josh Savage, on Flickr 20160315_182125 by Josh Savage, on Flickr 20160316_194210 by Josh Savage, on Flickr next up was the gear box this wasn't easy but managed to hoof it out and give it a clean up 20160319_153355 by Josh Savage, on Flickr and replace the crank oil seal, while the gear box was out i thought it would be daft not to replace the clutch with a upgraded one, i went for the black diamond stage 1 clutch 20160319_133324 by Josh Savage, on Flickr it was then onto the oil cooler, simple kit and fit okay 20160307_175816 by Josh Savage, on Flickr 20160320_151443 by Josh Savage, on Flickr before someone comments I moved it from here after finding out the bumper did fit. then while the engine had no oil I replace the sump and fit a windage tray at the same time with fitting the windage tray you need to remove the pick up. with removing this i noticed it had some swarf in it so i gave it a good clean out. 20160319_163309 by Josh Savage, on Flickr 20160319_163739 by Josh Savage, on Flickr i have no clue where these bits have come from, but its a 150,000 mile engine and it runs sweet so until a random noise appears I don't fancy stripping it down. now that the oil system had had some tlc and so has the cooling system i ran the car up to temp the bleed the system and to make sure there where no leaks. the cooling system was fine but as soon as the thermostat in the oil cooler opened there was a leak, now this wasn't from the union but from the core its self, after contacting the supplier i got it off explaining this most i got was its my fault, but I can send it back if i want but this can be a timely exercise and could cost etc. etc., with me been in a rush so that I could get to the race track I went to Mocal them self who I explained everything to them, I sent it on the Friday and by the Monday I had a new one (they tested the old one and found a fault) while the above was been processed I managed to get the spot lights replaced with some cheap ones (cant see point in genuine for a race track) 20160305_153226 by Josh Savage, on Flickr 20160303_175203 by Josh Savage, on Flickr 20160307_180016 by Josh Savage, on Flickr when the new oil cooler had been fitted and ran up I fitted the BBS that had new centre caps and new tyres 20160326_144247 by Josh Savage, on Flickr 20160326_144553 by Josh Savage, on Flickr then it was onto elsecar at the races it scrubbed up well FB_IMG_1460313623885 by Josh Savage, on Flickr FB_IMG_1460666698429 by Josh Savage, on Flickr I even put the back seats in so that it didn't look too bad. after elsecar it was time for Cadwell, the usual check where done and the back seats removed got there and it was damp but ive done some wet TD's so no real issue. did a few session in the damp/wet but it blew over and the track was starting to dry up nicely after another session or too i went back out to come round Chris Curve at 60-80mph ish there was a bang the car dropped and pulled the left i some how managed the control this and pull just onto the grass the bottom pinch bolt had failed. there was damaged to the wing and trim but nothing else visible at the time 20160414_105354 by Josh Savage, on Flickr after talking with the guy who towed me off (he races mk2 8vs) i needed bigger bolts that what was in it so after some begging i fixed it in the pit lane with the help of the lads who came in their car, i got back out and was getting into the flow again, i didn't beat any pb's but was happy to get back out also got some photos from the morning session FB_IMG_1460670170997 by Josh Savage, on Flickr FB_IMG_1460670228847 by Josh Savage, on Flickr so an eventful day but fun none the less i have since made sure nothing is twisted at the front and it isn't but the tracking has been knocked way out so next week i need to get that sorted - next thing I'm looking at are seats as it still throws you about even with harness. and some aero catches for the bonnet as it doesn't like staying shut bit of a update, with the first Nurburgring trip 54 days away I have started with prepping for that so I've ordered some goodies, the first is some gauges so I can see what is happening with the engine (oil temp, oil pressure, and volts) - not got a photo of the as without these been turn one they are just black next up is some aero catches to keep the bonnet planted 20160427_183235 by Josh Savage, on Flickr and next up is 2 bucket seats, because as good as the harnesses are I just need something else to keep me in the seat so I got these 20160427_200445 by Josh Savage, on Flickr along with some sliding running, rather simple fit to-do between the rain 20160430_165514 by Josh Savage, on Flickr I've also ordered a new clutch cables as the current one was clicking/sticking while on the track it did hold the clutch on but didn't feel very nice little update took the golf to a local classic car show, put it in the show and shine area and gave it a clean. When they called for all the golf to come through for judging I wasn't going to bother but as I was near the car I thought why not. I pulled it in and came away with best golf award, not bad to say I bomb in round a track ThorsbyHallClassicCarShow2016-56 by Josh Savage, on Flickr 20160502_121725 by Josh Savage, on Flickr I also had ordered some gauges (oil temp, oil pressure, voltage) first up was to mock up where they we going 20160505_162126 by Josh Savage, on Flickr looked at sitting them here but the brakets fit but not the gauges (had a little bezel on them) so found that they would fit here 20160505_171915 by Josh Savage, on Flickr sit just nice and can be angled towards the drive. next up was the wiring volts is easy, the oil pressure and oil temp I pull of Nige's thread which helped 20160505_181446 by Josh Savage, on Flickr 20160505_181441 by Josh Savage, on Flickr I know though some reading that the oil temp can be 10c out I will put a 't' piece in so it will have its own sensor but for the time been I will leave it 20160505_191855 by Josh Savage, on Flickr


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sava001006 Part of things Posts: 12	Sav's 1991 Golf Mk2 GTI 16v - Update - It lives - 10/02/2018 sava001006 @sava001006
	Oct 1, 2017 11:55:39 GMT Select Post Deselect Post Link to Post Back to Top
	update time been using the car a little bit and generally enjoying it, I took the car to modified nationals over the bank holiday (I know chav fest) but the camping and the laughs are what I go for because I was leaving as soon as I could after work I come to work in it and gave it a wash there 20160527_130552 by Josh Savage, on Flickr was a steady drive down to Peterborough ran really nice, but on the Saturday morning when parked in traffic (on and off clutch) the clutch wouldn't dis engage meaning I had 1st gear or stall after realising this I pulled over at some of the lads pushed the car onto the stand I was on, under further inspection the clutch arm was bent and the starter motor had given up the ghost. 20160528_100628 by Josh Savage, on Flickr so on the Sunday (day we leave the show) I called the AA out and they come to have a look, after much thought it needed to be recovered home, but with it been so low it cannot be dragged so 3 hour wait and the low loader turned up 20160529_182014 by Josh Savage, on Flickr a few mates stay behind to make sure the AA did come, the line up was wrong we had a rover BRM - normally have head gasket issues Alfa mito - need I explain MG ZS - supercharged and is on its second engine VW - know for reliability but the only one to break 20160529_180128 by Josh Savage, on Flickr then once home and after I recovered from drinking far too much I wanted to take the gearbox out and check it as clutch arms don't just bend and with nurburgring 3 weeks away it needed to be 100% 20160602_101015 by Josh Savage, on Flickr before someone comments the car was solid jack up like that, out come the gear box and a quick looked showed this 20160601_155507 by Josh Savage, on Flickr this rod was welded to this plate 20160601_155511 by Josh Savage, on Flickr lucky I had a 16v gearbox that I picked up cheap so I made a good gearbox out of the both of them also putting fresh oil in the box a quick test and forgetting the starter motor wouldn't work I quickly got hold of a new one bolted it in and turned the car on hoping I could get gears and the gearbox feel nice, phewww it did work and felt a lot smoother that last time (new gearbox oil I can imagine helped) been trying to put miles on the car just to make sure that it is working before I go to the ring. me and I friend come up with a bonkers ideal to sticker the car up (race car style) for the ring because he does sticker etc so I could get it done for materials and beer money. at this point I had been looking on YouTube at various car blogs and thought I would have a go to - when filming this I really enjoyed it too it is a 2 parter as the car isn't finished yet but a part 1 can be found here any comments on the video will be appreciated (I know about the rattle at the first bit of the video but It does get better) 20160604_225950 by Josh Savage, on Flickr there are more to go on - race numbers etc but I'm really happy with it so far, I know its a bit marmite but its only fun. Blis - thank you for that reply I have tried some new filming on one of the up coming vlogs, as this one was half filmed when I put the first one up. eventually managed to finish up the livery, I know its a bit loud but I really need to get some better photos on the DSLR rather than the ones off the phone. Livery by Josh Savage, on Flickr Livery by Josh Savage, on Flickr Livery by Josh Savage, on Flickr Livery by Josh Savage, on Flickr and naturally for those who are watching I also have part 2 of the vlog thank you for the compliments, its now onto he last couple of bits before I head to the ring on Thursday, the most important bits were that I have a leak coming from the bottom radiator hose, and a leak coming from the flange that bolts to the head just under the dizzy. the bottom radiator hose was just the clip so I swapped that out for a jubilee clip, the flag I replace which was a pain to-do as the bolts where that cleaver so when I put it in new bolts were added. once I filled the system back up and started the engine to circulate the air I noticed the warning on the dash would go away, now I knew none of the wires were a miss and the water level was up to the max, but one I turned the engine off and on again the light went out. the next bit to-do was the sunroof seal, this wasn't leaking but it was destroying the paint round the sunroof gap so I ordered a new one and fitted it. I managed to get a genuine one from Germany for £30 cheaper than I could get one from in the UK. now any one that has taken a sunroof out of a golf will know what a pain it is but I soldiered on anyway. and once again I vlogged about this don't know if anyone likes these videos but they are rather enjoyable to make also while on the ring prep I noticed that my exhaust was blowing just a little bit (round where the back box meets the centre box) so I took it off and re sealed it using tiger seal as someone told me it works a lot better than any exhaust paste so off with that and seal it all up 20160618_161448 by Josh Savage, on Flickr shoved it back on and clamped it all on and it worked a treat. while the weather was playing ball I wanted too quickly check that the co reading was at 2% as it should be I managed 1.9% so I just left it as I didn't want the throw it completely out - I took the photo before the ready stopped climbing 20160618_211444 by Josh Savage, on Flickr last up was to put the track wheels on ready as its easier to drive over there with the wheels on (and I don't have the space to carry 4 other wheels) so this is how it currently looks 20160617_175502 by Josh Savage, on Flickr well its about time i updated the thread with the Nurburgring shenanigans it may not be as i depth as copes but i vlogged all of it so you can always grab a cuppa and watch the first 3 parts (5 parts total) i didn't want to upload them all in one go as that would be spamming the subscribers. i think the best video to sum up the trip is a little clip that i made before i edited the main vlog just in case you enjoy a good vlog here is a link to the vlog playlist the ring ones are vlog 4 www.youtube.com/playlist?list=PLyfMqWS_famvCYK82O6V50XqVpuSKpJUa right i know vlogs are not everyone's cuppa so here is a brief report of what went down day one was the usual travel to the port, i was meeting up with everyone at a local mcdonalds just before the port (couple of miles off) so with the car packed music on i went to start the golf and nope, it wasn't having any of it so out come the charger. this wasnt a quicker charger so a trip to my dads work and borrow the jump pack and the car was started. i can only put this down to it been stood for a couple of days but i was already 20 mins late for meeting up with the guys so i took the jump pack with me just in case. once met up with the lads it was onto the ferry. i wont bore you with the drive but the car ran well it was comfy to say that it was a full bucket seats with the 4 point harnesses. skip to the Saturday where it hammered it down most of the day meaning that we had to do something, so a trip to the ring werks for a look round the museum which was really good even sat through the 4D movie/video of the 24hrs race which was quite good after that because there was no tourist time we went karting which was great fun right onto the part we drove 400 miles for, the ring. it was open on the Sunday and the Monday for tourists so on the Sunday at the crack of dawn i got there got some laps sunday with the first 2 i was taking it steady as i was still on edge if the car would make it but after the initial 2 laps i was fine. the sunday was good but it can have a lot of traffic. on the monday i managed to get a 11:06 which is a pb for me but i know isnt a quite time but as I'm sure anyone who has been to the ring knows you have todo a lot of laps to get used to the track my fastest lap is this one that about sums up the ring trip without going into too much detail if what i must say is if anyone is think of going do it, thhe place is amazing and as of day its a month before i go again so i cannot wait. Here are some snaps i took while over there Ring by Josh Savage, on Flickr Ring by Josh Savage, on Flickr Ring by Josh Savage, on Flickr Ring by Josh Savage, on Flickr i think that the livery that has been put on the car looks great when on the race track racetracker_1631899_23973 by Josh Savage, on Flickr racetracker_1631901_23972 by Josh Savage, on Flickr update time and its back to the ring again, nothing much happened between the other trip in July apart from going to a couple of car shows, any way the trip. i was heading for an overnight ferry from Harich so spent all day on the wednesday getting the car ready, putting the back seats in and making sure i had tools etc, it come to set off to meet up with the other guys and i noticed some fluid on the floor on the drive in front of the bumper, it was engine oil and the other thing it can leak from there was the oil cooler. so 5 mins before setting off i had to take the oil cooler off and loop the sandwich plate. the oil cooler (Mocal - surprise) had split but it hasn't been hit by anything as you can see no marks on the cooler, this is the second one that has gone and it was mounted correctly so that it could move without vibration so i will be contacting mocal again and seeing what they can do - I'm hoping they have a up rated version as the current line is s** and really ** poor. but back to the story i got the car sorted and met up with the guys, and just managed to get onto the ferry, the last couple of cars 20160810_221826 by Josh Savage, on Flickr note the Citroen DS there was at lot of them and it turns out they have a 4 yearly meeting in Europe. once got into Holland there just is the same old motorways, and just a hassle free journey onto the track the first day that the track was open it was raining now i normally would go out onto the track but i thought i would just so that i could get a feel for it again and the track is pretty empty, i didn't do any great time and the video isn't great so i haven't uploaded it, the next day the track was closed so onto the karting once the track was open again saturday/sunday/monday i got some laps in now my aim for the trip was todo a sub 11min lap which isnt quick but i would be happy with that, my first run out was a 11:37 as 2 yellows and traffic killed it, they next few out were really good, getting the sub 11 but i still like to keep trying for better, by the end of sunday i was on a 10:12 which i was blow away with, the optimum lap was 10min dead so i was determined to get a sub 10 but the track was only open 515 till 730 so not very long due in the sunday session i took some friends out that have never been round so i set up a face cam the morning before the tourist time i stripped the back seats and everything else that had any weight the Monday evening come and itching to get on track i got there early and naturally it was open late but i got out, drive really well with just me in the car and got a 10min dead, there was only 25 mins left so let the pressures down to 24psi front and 25psi rear and back out, chris wanted to come with me so face cam set up and off back out i drove and did some mad over takes (waited till i could see indicators) but it had a yellow in the first sector so i was doubtful i would be able to get the sub 10 i wanted but i managed it 9:57 over the moon with this the car has been amazing i was happy the car ran just cool enough without the oil cooler, but the golf did have some issues rear bearing had gne and the front engine mount is dead too but i managed to nurse it home. got some of my favourite photos from the trip too racetracker_1862841_26950 by Josh Savage, on Flickr got some good air here so it shows how much i was pushing 20160813_104253 by Josh Savage, on Flickr the 3 cars we took 20160815_211229 by Josh Savage, on Flickr standard tourist photo with the bearing been gone and the golf is on daily duties till i sort a works car out (don't worry it will be vag most probs be a golf too) i ordered some Febi baring and install them 20160818_193836 by Josh Savage, on Flickr 20160818_193839 by Josh Savage, on Flickr the car currently sits on RA's and standard interior, but it still needs a engine mount so looking at a vibtecnic one as a bit of a upgrade right update time as it has been a while, i have been flat out with work and as i mentioned before the car say with the standard interior and the ra's on it for a little while till i bought a new daily which is another VAG (seat leon) so back to the car, i was itching to get back onto the race track last time i went on a UK track was (14 april) so i need to strip the interior out put the buckets in and the harnesses, so this isnt the longest job i didnt get any photos as you have seen it many times before but i did decide to vlog it also before i went to the track i needed to replace the engine mount as that has seen better days too, i decided to go for a vibetechnic fast road one. i didnt want to go for the race one as i didnt want it to be too harsh on the UK roads. Engine mount by Josh Savage, on Flickr this was a easy fix and that was the track prep done, now this is where i forgot to take any photos but it was onto Blyton Park really excited to get back on track, the day went the usual way doing the standard sighting laps, at this point i then checked the tyre pressures and set them to 25psi and the front and 27psi at the rear. i found through the day this was spot on. i took a couple of friends out and i set the face cam up to see any reactions i could get the last time that i was at blyton i was lapping around 1:30 ish, this time out i was lapping at 1:24 to 1:25 and i got a couple of different angles on the car too really happy with the car and I'm still not getting anywhere with the oil cooler just incase your wondering, also here are the photos from the track Blyton Park 09/10/2016 by Josh Savage, on Flickr Blyton Park 09/10/2016 by Josh Savage, on Flickr Blyton Park 09/10/2016 by Josh Savage, on Flickr now the car just needs a check over, and i want to look at the rear brakes as i suspect that one might be sticking slightly so the car is on axle stands. after the hassle of getting the car on axle stands i have created some little ramps to help me Ramp by Josh Savage, on Flickr thats where the car currently sits hopefully going to squeeze another track day in this year before some big changes for the golf come in little update on the oil cooler issue, as some of you know ive had 2 oilcooler split on me, one leaked as i mocked it up and the other leaked as i moved the car on the drive - both mocal, so when the last oil cooler went i sent it back to the place i got it and hear nothing else, then i got a email saying they might not replace it as ive put too much pressure through it and i might need a uprated part. with this i got on the phone and to cut the call short i explained to the company that i will take them to court for selling a item not fit for purpose. (this got me the refund) so with the money i went at got the same oil cooler just made by motamec one 20161022_145901 by Josh Savage, on Flickr right onto the fitting of the oil cooler i decided to mount this in the same position just altered a bracket slightly (extra rubber washers added) 20161022_155154 by Josh Savage, on Flickr simple enough fit, ran it up to temp to make sure there was no leaks and bingo all sorted. i noticed the front end was lookng a little rough so i nipped the shop and got some hammerite and gave it a good coat (terrible photo i know) 20161022_181333 by Josh Savage, on Flickr then the front end back together 20161023_160633 by Josh Savage, on Flickr the cooler looks protected by the front grill 20161023_160643 by Josh Savage, on Flickr also i noticed while checking the brakes and what not over that the inner arches had go spots of surface rust, so wire brushed them all back and painted them with some under seal 20161018_183029 by Josh Savage, on Flickr i also sorted the rear sticking caliper out but didnt get a photo thats all i managed to get done this weekend, next up is the side skirt that seems to want to come off so that needs re fitting, and to fit some new backing plates (looking at doing some brake ducts too) well, apologies for the delay in updating this thread, work, and setting up a business takes more time that you would believe. But to catch up after fitting the oil cooler I attended Donington Park for the last time of the year, i did the usual check on the car and it was looking good. once we got there the weather was brilliant, it was a cracking day the car ran a dream the weather was great. got some video of inside the car I also took one of the lads who wanted a lap out with me, I will leave you to decide if he enjoyed it or not after the day I put the golf away and enjoyed the festivities but the winter build was looming, i have lots of plans for it before end of march (first track day) the first up was to de sticker it as a new livery will be going on it. there was silly amount of stickers and they took some getting off. after that the marks that they left needed polishing out so the car got polished. Who said that race cars cant be clean 20170115_154326 by Josh Savage, on Flickr 20170115_154307 by Josh Savage, on Flickr you will notice that there is a door missing, this is because i managed to pull the paint off the door so that was at the body shop. for those into videos i started a weeky vlog going live on the Mad Man Racing channel so if that your kind of thing please watch it and let me know what you think. if not i will do it the old fashioned way too! next up ive always wanted a mean stance to the car (hate using that term) but i wanted it to look like it should be on the track so i got these fibreglass arches from poland. 20170204_145602 by Josh Savage, on Flickr the purest might want to look away 20170116_200910 by Josh Savage, on Flickr with installing these it gave me another 2-3inch wider. but to get most from them i have rolled the arches giving more room and screwed the arches on with stainless steel hardware another vlog wheels should be here soon so the arches will be filled. Right, I must apologise for the lack of updates, I completely forgot about updating the thread, but fear not I'm back once i put the arches on it was time for the wheels, now i wanted a Motorsport vibe to the wheels bud didn't want to spend silly money on them either, so i chose some 15x7 Rota grids in white, with Yoko AD08Rs, ive heard good things about the tyres so wanted to see what they are like. 20170127_210308 by Josh Savage, on Flickr 20170127_210251 by Josh Savage, on Flickr 20170128_114218 by Josh Savage, on Flickr tyres sizes that I went for are 205/50/15 as there is a great choice if i decide to go for a different tyre. and i really love the fitment on the wheels, was itching to try out the wheels so they went on the golf 20170128_142157 by Josh Savage, on Flickr 20170128_135657 by Josh Savage, on Flickr 20170128_135649 by Josh Savage, on Flickr I'm sure by now you will know i run a small company selling car parts, i like to try all our products so I wanted to polybush the front arms, this was a nightmare as the bolts where solid but after using a long bar they come off. I didn't have a fancy press so i just burnt the bushes out. 20170205_163254 by Josh Savage, on Flickr one they were burn out i cut the metal collar that was in the arm. i wire brushes the arms and gave them a lick of paint so that is looked all smart, and put the new bushes in them. Didn't manage to get a photo of them on, but I'm sure you will be able to imagine what they looked like. now that the new wheels we on the ride height needed to be lowered but when i had a good look at the APs they has fluid on them and seized. (i got them second hand and they were well used then) so i looked at what i could put on instead, I didn't want to spend silly money on the suspension as I'm only a avid track day goer not a pro. but I didn't want something that was damping adjustable in the end i went for SPAX. they seem really good quality and a very reasonable price. was a easy fit as the impact gun sorted them all out and put the new ones on. apologies i didn't really get a photo here either (videoed it all - will put a link at the end of this post) after a lot of video been brought up from the ring and generally bad accidents from the track. And the fact that a week or so before my last Nurburgring trip 2 brits in a 25 Year old car tragically lost their life. with this i wanted to improve the safety as much as I can. so the choice to put a full FIA bolt in cage. i went for a safety device one as they did a full kit with door bars and harness bar. this was a challenge, we set about in the morning taking the seats out and the carpet and set about mocking the parts up, so the main loop went in first, then the front section followed by the bar in front of the sun visors, then the door bars, all tightened up and then the holes drilled, all took out and then the main roll hoop feet place welded in, I was very please by fit of these and they went in no problem. then once the holes all drill the cage went back in and fully bolted up. carpet trimmed and seats in. - i will admit writing that made it sound like it was a easy job. While it wasn't hard it was time consuming to make sure it was done correctly. but once it was don't i was very happy with how it looked. 20170304_141406 by Josh Savage, on Flickr 20170305_144130 by Josh Savage, on Flickr 20170304_191425 by Josh Savage, on Flickr 20170304_163957 by Josh Savage, on Flickr 20170304_122330 by Josh Savage, on Flickr now i know that you the 16v isnt a bit power car but i want to keep it 16v till it doesn't work as i like its revvy characteristics so i decided on some cams and a 4 branch manifold. i when with a autotech cam while had mid rage power gains and a Miltek manifold. Me and a good friend of mine set about at 11am and managed to finish at 4am the next day. anything that could go wrong did go wrong, the less the said the better. its all covered in the vlog. in brief the manifold was tackled first, and this required the sub frame to be dropped, this meant undoing some bolts that haven't been undone since factor (I guess) and both side the captive nut sheared. so cut the chassis leg open weld them back in and then off with the sub frame. when my friend was doing this i wrapped the manifold in some titanium heat wrap - sounded fancy 20170318_124805 by Josh Savage, on Flickr we replaced the exhaust gaskets and went to bolt up the manifold to the exsisting to find that they were 2 diffrent sizes, so a bit of cut and welding sorted this right out. 20170318_193143 by Josh Savage, on Flickr might not be the neatest but was solid and no holes none the less next was the cams, so off with the cam cover, while this was off i gave it a lick of paint and detailed it 20170318_113607 by Josh Savage, on Flickr 20170318_131526 by Josh Savage, on Flickr when i bolted all the cams up checked the timing etc it was time to bed the cams in, 2000rpm for 20 mins (molegrips on the throttle helped with this one) next and the last bit was to sticker the car up and give it a service, really happy with this livery. next up after all of this was the first trackday of the year, we decided to give rockingham a go as ive never really don't that track and it was at a good price with rockingham direct, I was impressed by rocking ham really chilled out, and quite day. there was no photographer but got some good footage using a new 360 camera ive got. also did a bit of a montage if anyone is interested. thats me about up to date, just another track day and a nurburgring trip. stay tuned as that will be next still reading??? next up was another track day at cadwell a couple of months later, i was really keen to go to cadwell as i had don't the track before all the major changes, in a word the car felt miles better, i couldnt tell how much at rockingham as i was getting to know the track but damn at cadwell i took 6 seconds a lap off my time, I'm not at 1:59 which I'm massively happy with. i would love to show you a fast lap but i set the 360 up wrong... did get some photos Cadwell park 2017 by Josh Savage, on Flickr Cadwell park 2017 by Josh Savage, on Flickr Cadwell park 2017 by Josh Savage, on Flickr Cadwell park 2017 by Josh Savage, on Flickr the car did have a couple of issues the first been my rear exhaust rubber gave way, but fear not the cables rescued me. and the engine makes a funny noise, rattly - i found out the issue later then onto the trip to the ring. to sum it up it was 10 days, 31 laps 1 accident (my friends car) and a 9:28 pd set i don't want to bore you with everything that happened as i covered it in this video, its not the same as the others i think it has better content, it also show me breaking down on the first day also set a new pb, which is 29 seconds quicker than last years the new set up is epic so that where I'm at, we currently have another 7 days trip planned for next month and i have a huge list of bits to sort but i will keep you guys updated this time Nurburgring prep now. there are a few little bits that i want to sort before the last trip to the ring next month. first up was the centre section of the exhaust needed wrapping. This is because the heat shield has come loose and the brackets corroded so i thought why not heat wrap it. i know this might not be the best idea but heat wrap isn't much money and its worth a shot. lucky the exhaust has recently been off so none of the clamps were rusty, so with a few swift hits with the hammer off it came. and all wrapped it went back on. i cant believe this bit took so much wrap (10m) but by the by it looked a neat job when done 20170902_134803 by Josh Savage, on Flickr next was a little bit on the engine, i wanted to change a couple of clamps on the power steering as i think its weeping slightly so i wanted to change the twin scroll (one on the right below) to a Jubilee clip 20170902_170921 by Josh Savage, on Flickr when i was under the engine bay i did notice that the bolt on the altinator had come loose 20170902_115245 by Josh Savage, on Flickr so sourced a longer bolt along with a was and a nut for the other side, just as a precaution 20170902_120425 by Josh Savage, on Flickr next up while the car was on axle stands was the brakes, i beilieve when breaking it pull just to one side. the last time it did on the old caliper i lubed up the sliders and jobs a good 'un. so i did the same with these, gave them a quick wire brush to get rid of any surface rust and then a good helping of copper gease 20170902_162210 by Josh Savage, on Flickr 20170902_162217 by Josh Savage, on Flickr 20170902_162427 by Josh Savage, on Flickr while the caliper was off i checked the pads, they seem very well after 31 laps of the ring. so grease up and re installed 20170902_162223 by Josh Savage, on Flickr and all back together 20170902_163118 by Josh Savage, on Flickr that was it on the golf, the only bit left is to fasten the carpet down in the boot as it keeps moving and the side skirt needs some sorting. Thats for next weekend. But while the weather was nice i cleaned the Beetle as it looked neglected 20170901_174019 by Josh Savage, on Flickr


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slammedorion Part of things Posts: 549	Sav's 1991 Golf Mk2 GTI 16v - Update - It lives - 10/02/2018 slammedorion @slammedorion
	Oct 9, 2017 8:10:53 GMT Select Post Deselect Post Link to Post Back to Top
	Looks great Use red brake grease on caliper sliders not copper...
	Last Edit: Oct 9, 2017 8:11:32 GMT by slammedorion

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sava001006 Part of things Posts: 12	Sav's 1991 Golf Mk2 GTI 16v - Update - It lives - 10/02/2018 sava001006 @sava001006
	Feb 9, 2018 7:52:24 GMT Select Post Deselect Post Link to Post Back to Top
	a lot has changed since I have updated this, but I went back to Germany and had a fansatic time between the rain and what not, also got some really good photos this year too the place we stayed it was brilliant just down the road from Adenau the golf was well behaved apart from the exhaust started to rattle, it looked like one of the exhaust bolts to the mid pipe had come look but luckly i take a full tool kit and spare nuts bolts etc also my first had a bit off an off on the track so the car needed some tracking doing as it had a pull to the left, so we nipped to Ring spares who sorted us right out other that that it was a great visit, if you want to see the videos which go into details just click the link below www.youtube.com/playlist?list=PLlENZKEoa8pQdlUzSI4iiGjuCoPw654gS there a few videos there so grab a brew to watch em all while I was in germany i could help but think the 16v engine isnt really quick enough on the Nurburgring so I send some messages around and got a BAM engine. While I know i could go quicker with the 16v it just mad sense to go 1.8t now I haven't got a lot of photo documenting the engine, i have video'd it (i know some aren't a fan but my other hobby in photography & videography) the videos can be found in this playlist under winter build section www.youtube.com/playlist?list=PLlENZKEoa8pSyS-6XOT2j-W1u1Ml7RS-J so the engine as previously mentioned is a BAM unit out of a audi tt we actually removed the engine ourselfs of a guys driveway i want the install to look correct and not just thrown in so while the engine is out i gave it a service with new belts etc and painted the block with black and crackle blacked the inlet and rocker cover also while the engine is out i painted the engine bay, while it isnt perfect it made it look a hell of a lot better the engine was mounted up to a 02j gearbox (that was cleaned and painted too) and then thrown in the engine bay after the engine was in I bolted up the i beam with new polybushes and the slam pannel was cut to make room for the intercooler I also made a little bracket underneath it so it is mounted solid, so that i could get the intercooler pipework to fit, so i little custom bracket was made up from here i don't really have many photos, but i modified the pedal box so that a DBW pedal would fit the wiring has all been done, i sent my loom off to get converted and for the immobiliser delete i have also sorted the exhaust and water lines out, just need to sort the last few bits and see if it all works. there is a lot more details in the videos so if your into the details give them a little watch hopefully i will remember more photo in the future


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jollyroger Part of things Posts: 189	Sav's 1991 Golf Mk2 GTI 16v - Update - It lives - 10/02/2018 jollyroger @jollyroger
	Feb 10, 2018 14:14:29 GMT Select Post Deselect Post Link to Post Back to Top
	This is brilliant. Would love to build something to use for roadtrips and track days. Keep up the great work, will head to youtube to watch your vlogs next.


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sava001006 Part of things Posts: 12	Sav's 1991 Golf Mk2 GTI 16v - Update - It lives - 10/02/2018 sava001006 @sava001006
	Feb 10, 2018 18:15:42 GMT Select Post Deselect Post Link to Post Back to Top
	Feb 10, 2018 14:14:29 GMT jollyroger said: This is brilliant. Would love to build something to use for roadtrips and track days. Keep up the great work, will head to youtube to watch your vlogs next. cheers buddy, I'm lucky to have the space to store it and use something else as a daily bus big update time. so I got the pedal box all back in the car and put all the boost pipes on. The next task was the exhaust system which I have been dreading, one its a challenge doing this when the car is on axle stands, the other is that with the engine mounts i was unsure if it would actually fit on the car. so after fitting the down pipe it came aparent that the system would fit. so off came the front engine mount and some modifications where made 20180107_190936 by Josh Savage, on Flickr all i had done was taken 5-10mm off the mount to get the front of the engine to sit lower so the exhaust would fit 20180107_150307 by Josh Savage, on Flickr after having a fight the exhuast was on, with it been a 3 inch system there was no room to get my paw like hand in. Next up was the water pipes and the vacuum lines, the vac lines were simple as I had took many of the systems off the engine, with the think less parts on the engine less to go wrong. so the SIA system was took off, the re circulation system took off and the N279 also taken off. The water line I just measured up and hope for the best ordering from one of my companies supplies various 90 bends and metal pipes. I decided to move the expansion bottle to the left hand side of the engine so that i could keep the water lines short and not have them going all over the engine bay. 20180114_210402 by Josh Savage, on Flickr now the cal had all its oil line and water lines it was time to nip the Halfords to get some fluids for the car golf by Josh Savage, on Flickr then it was time to fire up the car. The car didn't turn over first but after some checking the engine had sized solid. this was becuase of the oil been drain for a couple of months while trying to get it to fit. so a braker bar on the crank to free it up and jobs a good un. I havent got any photos but i did video the first sart to check it out here ITS STARTED... well happy, the car didnt idle well but after a first with VAGCOM popped rount and sorted my throttle body out it idled really sweet. it was now just a case of putting the front bumper on, bleeding the brakes and going for a test drive 20180108_185129 by Josh Savage, on Flickr off i went to on a test drive, it did high light a few issues, the first been that the servo had given up on me and the throttle pedal was a little too high. so it was time to fix them golf by Josh Savage, on Flickr and back on a test drive the car was epic, the sound and the feel of the engine is great for anyone who is thinking about a 1.8t conversion then i would recomend it. I did video the first drive out which on Wednesday (14/02/18) goes live i did managed to grab some photos too golf by Josh Savage, on Flickr golf by Josh Savage, on Flickr I'm currently halfway through taking the livery off the car, don't know if we are putting a new one on (for advertising) or leaving the car shiny for a year


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