5 GT Turbo 11 years later silver bullet comes home

[Duncan Grier]

I know the older 1.8 20vt / 5 speed setup well having used in my old vag 5 many years back, used the newer k04 flavour tfsi lump (s3 etc) and 6 speed manual box in the vx220 conversions and know these well but far from an expert on wider range and options.

The 5 pot and dsg a learning curve for me and going syvecs but part of the fun, I historically stayed oem vag managment and had custom map and turn off all the stuff not needed. This allows for easy diagnostics via obd2 port and off the shel parts and maintenance while keeping car on its own obd2 port for the same reasons. Never agreed with making myself a SPOF for owners going forward other than the custom mounts, shaft design etc but most of the work is R&D to get it reliable and as per requirements.

Just drop me a PM if you have any questions and try my best to help

 

[gordini stu]

Cheers
I will take you up on that
Knee deep in tractors for my old man this Christmas break so I get him out my hair for a fresh start on the gordini in the new year .

 

[Steve Swan]

Cheers a fresh start on the gordini in the new year .

Sounds dangerously like a new years Resolution and we all know what happens then....,

 

[Duncan Grier]

Sooo bit of a small update, dedicated a few evenings power hours and lost many hours seperating oem bits for sale, find things I never knew I lost and general clean up ready to make chassis dolly and warm upto some fun stuff.

Usual dribble of pics for those interested lol. Was like having a holiday with some actual steel to weld (used 40mm box, 4mm thick?) and cranked welded to 7/10 and 8/10 wire speed.

Will drill and weld blind nut and get some threaded bar tomorrow to make adjustable plates for oem jacking point to get car 100% true before heart surgery cutting

 

[Steve Swan]

Creative Chaos is better than Tidy Idleness

 

[Norwich Nick]

Still here for the ride and power hour updates

Usual dribble of pics for those interested

 

[Duncan Grier]

Sooo had @Chris74# pop over today which enabled some extra play time granted

Was great to have a good natter, share renault restoration joy before getting on with job in hand, massive thanks to Chris for the help and certainly helped getting my alternative design together and adding a 5 to it

Did a @Big Steve - Raider and snapped a cheeky shot for the garage visit

 

[Chris74#]

Sooo had @Chris74# pop over today which enabled some extra play time granted

Was great to have a good natter, share renault restoration joy before getting on with job in hand, massive thanks to Chris for the help and certainly helped getting my alternative design together and adding a 5 to it

Did a @Big Steve - Raider and snapped a cheeky shot for the garage visit

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It was good to get over and finally meet you and the Silver Bullet in person! Lots of fun to be had with this one!!!

 

[Duncan Grier]

So squeezed a final few hours in before Christmas shut down..

In my focus to have mounted on oem jacking points overlooked a key element of full access from underneath to mock lift engine/cut floor etc.....

So plan b created with adding cantilever section and shorted middle bars, got most done other than last support bar usual flurry of pics below

 

[Adey]

Found some time to catch up, big changes but very much looking forward to where this is heading. Keep on posting as i enjoy the read when i get time Loving the jig thing you have built too

 

[Duncan Grier]

Thanks @Adey

 

[Duncan Grier]

So got back in the garage this evening for 90mins and finished off other rear section, measured 10 times and then called neighbour in to help for half an hour as a bit sketchy on your own and cut/welded bar shorter and got levelled amd car on......was soooo close to cut boot and get the engine under but time up.....got some time scheduled over weekend if not before and get it floating in place to finalise cutout and any bracing needed

 

[Chris74#]

So close now mate!!!

 

[Duncan Grier]

Ok so after 2 days, 3 bedrooms of full on decorating done and start of house renovation take 2....

Got in the garage tonight with one thing in mind .....only to not be able to find spare tips for plasma cutter so with neighbour popping in for moral support (and beer ) went all angle grinder

Fits better than hoped and suspect I can retain some of the oem chassis rail and beef up after cutting the inner section out but find out tomorrow when lifting engine into mock postion. After a quick measure up also look to have 2-3 inch under rear window height which keeps the box enginen in option alive for now.....

 

[Duncan Grier]

Made a start on engine, box hardware, wiring needs........few wins and some expense hiding but for now focused on getting together, cage made and on wheels along with carrying on with rot/rust repairs (sounds so easy when typed quickly lol)

All in all taking today as a small victory

 

[Duncan Grier]

Last update for 2022

Got a good run in the garage today, however mostly measuring, measuring and reviewing mounting options

Then worked out I can retain the drivers side chassis rail for now, spent more time playing with left/right position - engine 183kg, box 91kg (123kg with transfer box still attached)

Settled with 40mm offset atm but review again once engine in

Tacked a bit of 25mm bar in the back as a bit of a brace and further reference point

Then cut out pax chassis rail as dsg box fouls

Ran out of time to get an engine in shot.....do that next year

Roll on 2023!!!

 

[Chris Smith]

Cracking good progress Dunc…

 

[Duncan Grier]

Had a few sessions in the garage, with section of pax side boot chassis rail out engine fits fine and enough room to retain box engine in option rather than having to go full firewall but see once in final resting position.

Removed transfer box removed a few things off engine that are not going to be used

Had a bit of a mare on next burst in the garage and forgot I had wedged the engine to give rough angle while in last time and had a sheet over engine, pushing it back out you can guess what happened lucky all in all with minimal damage but not stopped me been mega pished off for a few days and letting my mind runaway with itself to potential unseen damage and cost of repairs.

In the end had a good luck tonight and feeling far calmer and will look to replace mashed boost sensor, squished braided oil feed (just to be sure, looks ok on outside) replace bit of damaged loom/plug and might even stick the broken bit of cast sump back on (bit of the webbing)

So note to self and you all, double check prior stage of any work fully before doing next, stay safe.

So beefed up engine dolly to reduce any future movement and while in paranoid saftey mode drilled and bolted in the extra bars previously welded to the new bottom bar....all good

Other than this have spent many hours documenting dsg conversion needs and starting to draw out wiring etc.

 

[Steve Swan]

We've all done it.......... It's still a pain in the Ass

 

[Brigsy]

Shit happens mate. It'll be sound though.

Progress getting it in the hole!