hi guys thought id share another one of my homemade projects ,all based on a homemade transplant ,all parts were from a 4motion mk4 golf ,the rest i made fit

had to make a head spacer needed the compression lower ,,

then its start chopping the rear axle to size

rewelded it up in place

then got a bit ampage on the go ,,i dont want these snapping off

axle shorternd

sorted

double checked measurement

more pics on there way

head off all valves re seated and skimmed

ill be makeing another turbo manifold,inlet manifold,etc

think it may work..

injectors arrived 2day

.

erm lots of fuel useage lol

I'm CHUFFED HOW TURBO IS SAT ,NOT TOO HIGH so bonnet should shut in theroy lol

oil return sorted and a start on the inlet manifold this afternoon

home made oil pipe,every little bit comes in

removed sumps as the early steel one fits and is cheeper to replace if i hit a hump lol

soon be ,,caddy moding time ...carnt wait ,

more chopping is needed lol

once racked moved sorted ,ill cut tunnel to suit

just made a start on the short runner

bit of bending here and there ,and it will fit ,

i reckon ill get a radiator and fan thown in there

may have to find another place for the intercooler

,i need to angle it more ,ill sort this no probs

trail fit of the propshaft

those garden bricks come handy lol

riped the old rear axle off, and oh dear dam std golf is short as well ,what a suprize

then thought ill trail fit the rear 4motion axle ,and yes,,more stress ,i shorted it too mutch ,as i only tuck a outside measurement of the tyres ,forgot about the thickness ,,lol

as u see from the rear wheel,looks ok thow ,so recut and welded a bit more on ,

seems better

looks more like a skatbord then a caddy lol

just riped carpets out ,to fit the clutch pedal

looking as well as the propshaft will be up in the tunnel ,may have to partly mount the gear selector on the top

just a quick homemade engine mount be ok with some weld and strenghers on it , so i can slighty higher the prop for a few more mm to rise the sump lol

haven't got mutch time at mo guys sorry

decided to beef it up a little more

well that ill do for that engine mount mount lol

next 6spd linkage needs to be started as

i mounted the propshaft right up in the tunnel

,

so remote will be welded best i can ,and i chop the cables to shortern them later,trail fit

few more bits done this after

just started on mounting the rear diff and axle

prop too short lol so ill soon sort that little joby out,,

flow ,which one day may be runing

and found a stronger coilpack pack for better spark gaps 40,ooo ,instead of my 10,ooo one ,rough idea of how it will be wired lol

quick zip around for intake holes

propshaft in

bit of welding just mount the axle

thought best beef the front up more ,we dont wont it dropping off now do we lol

bolted up

I've made this basic frame ,so i can move the rear axle in place were i need to weld ,so it will be sat approx 2.5 backwards shown in pic ,,then ill cut the prop to exstend it ,due to it been to short ,and be sorted afterwards

diff just about bolted up

,,,

then u can see the main rear hub mount is hitting the inner sill ,a bit of chopping welding here and there ill sort that

but managed to weld the rear track control arms up and fit them

so might as well fit the clutch pedal assemby 2moz

right thats the tempory fit of the axle to keep it held in place while i algine a few more bits

started on the rear arm mounting this after

I've a few more strenghing bits in side the mount to add before i start welding,,,

more welding up this after

then started on the spring mount

then stress happernd ,due to wear i amounted the rear subframe i carnt lower the dam wheel enoegh ,grr ,ill have to do some chopping 2moz make the buggar a bit lower

then quickly drillede and bolted in place

hit a small prob on the bulk head ,,nothing major ,so nipped a bit out ,as i wanted the hydrolic pipe in the rail,,

job done ill sort a fluid bottle later ...

just warmed the bendy steel pipe ,and bent it straight,,,you can just see,

then start on the shorting the drive ,as i thought this may help incase anyone wants to try it ,

first cut the drive shaft to size and make it in to a pencil point

then once grind out ready place both halfs flat agaist the angle iron ,and mig tac to hold it in place ,then just give the centre a quick weld in the centre ,

rocker removed

head removed and cleaned etc

checked all bores etc and cleaned plus decoked pistons ,

some nice copper spray to seal everything on the block

then split the std 3 layer gasket use the down part first

then another coat of spray and fit the head spacer to lower compression

another quick coat of spray fit the top part of the gasket as the middles not used and bingo job done ,

and did a final check of the timing as i dont want valve nicely wacking pistons etc lol

final pic of the head spacer ,somert else out of the way lol

started on other side 2day

INNER REAR WHEEL ARCH ALL WELDED UP

THATS THE MOUNT SORTED lol

nothing done 2day due to wheather so I've gone for more airflow so went and got this baby ,,,first my old one showing on the left and new one on the right

a nice holset hx40w with 4inch in and 4inch out lol ,,,,,

yes its big ,may take a bit of fitting thow lol ,,,

so a trail fit is needed....these buggars will thow out 44psi ,,my aim is anything or 15psi to 25psi which is 500bhp on these engines

i reckon i can make somert for it to work lol

finished the drive shafts of 2day ,,,

/that them done and fitted

and started on makeing a pulse manifold to help spool my big turbo up ,

right made a hour free night so made a collector ,,and let me tell you ,trying make 6 outlets into a t3 flange ...stressfull lol as usely t3 are made for 4 outlets,but i like to prove they can be fitted lol

bingo thats that bit sorted ,and i have to use a 44mm wastegat too as u can see the larger pipe

its close lol but clears

there will be more to aome at some point lol

right decided to shortern it a inch for rear clearance so i can add the external wastegate

then welded it up

its a bit close now lol

I'm a littleworried as the hot side is close the rocker cover ,but ,its not too inportant at mo

turbos a little close but missed with the bonet shut..

oil feed fitted,need to sort return ,which will be fun

going to fit the extanalwastegate pipe just enoegh roomi reckon

and a few more updates 2day

thats the manifold sorted at last

then made a oil return have to say what a little idiot that was lol,due to havein to make it fit thew the bendy pipes

then thought might as well sort the steering rack ,and make some brackets

shes close but clears nicely ,and has a good 10mm underneath

thats the rack nearly sorted just have to make another bracket and trim the inner wing holes more a little more movement ,

right we have some seats and harniss ,to nicely hold me in place lol

thought might as well fit antiator and trail fit a few engine bits,bingo things seem to fit too

and thats 2days progress ended ,may have a few more after I've sorted a few other things out ,,,

small update

just added a small suport for the engine as the old one looked untidy so made another

and added a homemade suport to save engine rock

and decided to make more clearance for the steering rack in the end lol

the a quick repair on the rear quarter pannel

just started on the wireing as i thought be better striping the lot ,then wire it were i need it to go ,on the lump ,bought a few extra bits/bobs of wireing/beeding/box of earth clips etc ,

just a quicky ,removed the old leaf spring hangers and boxed it up ,also adds a little more strengh ..

decied 2day as i want power steering on my caddy and due to moveing/riseing the steering rack ,as the propshaft was in the way ,,thought chuff ill rip the old vw steering coloum out and fit a electric power steering with varible steering ,,,bit of modifying should work a treat ,,as lots of vauxhall fit vw,,

yep and I'm another , first ripped the old coloum out and under tray so u can see the old bolt holes

then made some quick brackets so i can mount in the same oringle bolts holes saves chopping the dash frame to bits

roughly how that bit looks

then as mine was and adjustable coloum had to weld a coloum in place so i can use the mk1 cowling and switchers

then bolted the lot up in place

everything fits nicely ,

regards the u joint i split them and simply changed the ends so they clamp up nicely from the rack to the coloum ,and the steering wheel ,i cut it off ,put both parts on the lathe and stick welded it and drilled and peged it ,,,

only thing the under tray i had to nip a bit out for it to fit ,,,

thats the steering sorted ,,

small update had to modify the thottle body a bit as it was hitting the bonnet lol

bolted short runner up and checked revs ,,have to say works a treat

nicely missis the alti too ,,

started on some engine wireing ,loom is coupled up ,not tidy as i want to make sure its wired right ,when i set the ecu up

so engines in wireing will be trail sorted, oils in ,steerings sorted ,just need to get some pressure in the feul rail and see what haperns had it cranking over too ,and it have decent oil presure due to it shooting out of the pipe for the turbo feed,,,

update due to been bisy with other things ,

as i was going to use the v6 vectra coil pack which would have donre the job ,but soon as my boost comes in it would blow the spark out ,so yet again ,had to modify a coilpack with a better ohm output ,then i found the buggar is a lot wider bigger then the other had to make another adaptorplate for it to mount ,so here it is

looks like it was meant to be there ,lol,

just got to pick some ht ends up ,and thats the engine wireing coupled up ,ready for the feul and tank next ,,,somert else ill have to make thing is its were to put it,,think ill have to make one under neath so more steel is needed lol

little update before i attrempt to get it runing ....

coilpack modifyed

its getting a bit tight in there

and may get the header and washer bottle in too ,with a little mod

when the exhaust manifold and downpipe are heat wrapped to save melting things,

seems to be coming together if nothing else lol

not mutch to add ,but as i had a hour free thought id re make a inlet flange ,with some nice 12mm steel ,ill make sure this seales ,unlike the other flimy flange

http://tinypic.com/player.php?v=29bm53l&s=5

found this so it will have to do

i thought that ,but would have needing chopping ,so thought chuff i cut that one above ,made a 76mm baff mesh made too rings and added sound deading and welded it up done done ,as chuffing companys are simplely rips offs

small update started on the downpipe

then made the angles needed

checked to make sure it will clear the inner wing

then added the side pipe ,ok for a first attempt lol

some nice heat wrap on the go and aheat sheild made and poped on ,that will be another job done

bit of an update and also a bit more stress lol

as i had a wheel alginment and track issuise from trying to use vr6 hubs on to a mk1 to run 5 x 100 as i also really need the biggar cv joints ,

so i tryed to reeem the hubs out to fit the mk3 bearings and poped the 5 stud hubs in,as u can see the bigger mk4 driveshafts

then fitted the pollybushed std mk1 arms

then realised that I'm still knackerd lol ,as now i carnt make any calipar adaptors as the bolt hole thinkness are the same width and depth ,,blooody hell if its not one thing its another ,as i dont want to fit the 288 vr6 discs etc as they arnt great stopping power at fast slow down speeds after a few runs ,,

after a bit of lathe work and adapting a plate i had to do them this way so i could get the full use of the pads on the discs ,then tapped bearing out ,and beefed the hub up ,refit the bearing and hub and drilled thew and bolted the lot togther ,should be a lot stronger and do the joby

this is how they sit ,

stronger now

just had time to make the exhaust nice and Secure

i think we makeing some head way ,,next will be the gearbox mount ,,(i nearly forgot lol

and sorted gears all work nicely (all 6 and reverse )

had to change the mount it wouldnt fit lol

sorted

then the dam bolts sheared off so time to tap a bigger one in there

then ,its tight but it fits lol

carnt see that shifting anyway soon

decided to make a wiper arm ,,works fine too

another small video

http://tinypic.com/player.php?v=30vd81z&s=5

had a few hours spare so decided to get some bits sorted

first bit of inner wing welding

then had to make a differnert bottom inner sill ,due to my exhaust has to run under it

then added some heat wrap to keep the heat temps down a bit

had to order some more ,,,too ,as it soon runs out lol

then added some front brake flexis and made some new copper brake pipes

then just had time to make a new door bottom and repair door

thought id rip the other side out and bob a plate in

and thow some brake pipes in

and as I'm awaiting a few parts ,i decieded to solider a few joints

thought id better start on the floor welding 2day as it was more rottern then expected all the way under ,including the wishbone mount

didnt have any the same shape so flat plate will have to do ,mind it is thinker

and i added some extrea strengh on the wishbone joints ,

then wrapped the turbo manifold ,,this is why i welded it and didnt bother to polish it ,,

then if u noticed had to alter the wastegate as i forgot about the other pipe , so I've orderd a small flexi for it ,to save the pipe cracking

I'm not tempted to cut both floors out ,realiseing how thin the steel is and the channeling is flimsy ,on these golfs ,

this is cool as fook! wish i had the skills to do somthing like it :(

had to re mod the exhaust hole

then make another part with a flexi in

then like a idiot realised it was in the wrong end ,lol so more cutting was needed

and a few pics of the caddy at mo

slowly takeing shape....

and now noticed all need some either banded rims or some spacers on the rear due to the fronts sticking out a bit more

toying with the idea of steelies next what do u guys think,as i reckon it will give me the option or wider rear tyres for corners,,

a couple bit of welding this after ,as i ripped the old chassi tunneling out as it was dam flismy and spot welded which with a few wacks with the hammer came ,off ,,so thought it that all what holds the dam floor from been flimsy ,so thought chuff this ill make a new one from 3mm plate and 3mm box ,,

then got a nice buzz on the go ,with only one lump of hot weld in the ear lol

just checked inside and a nice penitration inside too

so lets see what may happern regards progress 2moz

a few bits this after as

after a quick wash i was a bit suprized and how good some part were ie ,rear bed ,engine bay, just mostly rought around th inner and outr sills etc anyway

finshed off the welding and chassi repair then re routed the brake pipes and added a few extra homemade rubbers to hold the pipes

nice to be able to jack the chassi and it not cave in lol

and removed the anti surge ring as I've been wanting to remove it for over 2months ,as that now will make the buggar sound nice and whistle,,,

few bit done and made today first thought id better finish the brake pipes off and bleed them up ,,

nice nipple and was the last one too,that those bleed up and we have brakes ,,first time

then realised i forgot to make a vacum system for the servo ,, so thought ill make one in the short runnner

i was going to weld a lump of tube but thought ,erm ill had a nice tight ribbed rubber and use the correct bore and fitting

next thing cut some lumps of servo pipe and warmed them up to fit nicely and shape the bends the fit around the engine

couple of shots of the pipe around the engine

then just a few patchers welded to the bed as its not straight

next ill make a handbrake ,just the finish the brakes off altogther ,but i do have a problem ,,, that is ,i carnt put a intercooler and radiator behind the pannel as there only room for the radiator grr ,evern tryed a side to idea but ,it wouldnt cool right ,,so looks like ill just have to stick the buggar on the front ,,,something i didnt wont to do ,, :banghead:

turbo smoke test 2day

http://tinypic.com/player.php?v=2ce5grt&s=5

had this after free so ,decided to try get a rad ,its not the type i was after i think i may have re modify to a bigger one ,bit this may do ,for a trail spin

not over happy but if it will work till i can sort a custom size radiator out ,,ill be happy

think I'm getting there and verything looking extra tight in there lol

i was just going to thow some tube on ,but i pref the square style,,

been a tad bisy with house but managed to sneak off for a hour lol .and due to rain thought id make a start on the rear bumpers, as the std ones were rottern ,so off i went for some scrap metal ,,this will do nicely,,,

cut some lumps out and bent it

got the plazma on the go

removed the plastic and welded some tabs fited the caddy reg lights , just needs a few bolts and i might make some corners depending what they look like,nice lump of stainless ,so shouldnt rot

awesome. can i have the engine to put in my polo ?

That is awesome! Make sure you keep us all up to date on it

That thing is going to funking insane. You seriously have some skills and insane patience. The only thing i don't like about this build thread is that there isn't enough welding :-)

Oh and Banded steels 100%. That way just have some huge ones on the back as you will need a fair amount of rubber on the road to turn this beast.

been following this on ukmkiv's too as POWERNUT, some good work gone into this project and the man who built POLOMODIFIEDBREAKINGFORSALE's vr6 6n polo.

hahaha this is insane , great foresight to simply see things work and making things work when you are faced with an obstacle!

i would love to have this kind of skill!

hahaha this is insane , great foresight to simply see things work and making things work when you are faced with an obstacle!

i would love to have this kind of skill!

cheers all ,theres plenty more to beef up and yet trust me I've enoegh air pressure for 50psi my aim is 25psi for 500hp ,and enoegh fueling for 550,,,but there will be plenty of test drives before ,i go anywere soon ,mind its not bad as its tuck me 3months to do everything pictured from standard to now ,mind i reckon it would be a hand full with its std 204bhp,, and the 6speed gears and reverse work fine as well as the rest ,,ill see if I've any time next week for a few updates

WOW! I've just read through all this and its an awesoem build, some very good work there!

I think the best wheels are the banded steels I presume you can make them too haha?

thanks nice reply yarh i dont get stuck for mutch wheather its makeing anything fit and modifying it ,,,,thers always a way ,without pulling you hair out

this thread is amazing. if you fancy selling this, please contact me

Bloody help!!!!

I must of took me about 3yrs to go through all this!! :-D

Sickk mate! I want a side exit.

wow, how long have u been on this? and the cost must be high... lol, oh and nice skillage, lol well done, want to c it finished, keep us posted.

LEE

wow, how long have u been on this? and the cost must be high... lol, oh and nice skillage, lol well done, want to c it finished, keep us posted.

LEE

cheers guys its just stuff i had sat around the garage really ,thought id thow in in somert to see if the engine was a runner after 3months of doing all the above work and wireing it runs ,, and I've not a lot of money in the whole of the project ,as i just wanted to build a evo killer ,, :-D and will handle like a skate board on wheels,

mind i did like this small smoke test video on the turbo,,,

http://tinypic.com/player.php?v=2ce5grt&s=5

Edited 25 March, 200917 yr by ADAPTORMAN

wow, how long have u been on this? and the cost must be high... lol, oh and nice skillage, lol well done, want to c it finished, keep us posted.

LEE

cheers guys its just stuff i had sat around the garage really ,thought id thow in in somert to see if the engine was a runner after 3months of doing all the above work and wireing it runs ,, and I've not a lot of money in the whole of the project ,as i just wanted to build a evo killer ,, :-D and will handle like a skate board on wheels,

mind i did like this small smoke test video on the turbo,,,

http://tinypic.com/player.php?v=2ce5grt&s=5

wow, whys it smoking that much? sounds sweeet thow :)

LEE

Mate just read through your thread and its soo F**King sweet soo much welding its making me want to learn to weld bad!! Did engineering but never welding. Whats with the turbo smoke though? Cant wait to see a test drive on this!! :thumbsup:

the smoke is from a oil feed as i wanted to make sure it was flowing right ,,,wont hurt anything ,,,well i went wheel hunting and hard to find somert in 5x100 to fit a caddy ,so I've fitted these mjust have to change the tyres the rears will 235/40 17 and the fronts 215 40 17 for extra grip

quick side veiw here too ,just needs some 20mm spacers on the rear so i can fit 235 40 17 ,,should help

I knew I recognised this! You live down the road from Dearne Valley College don't you?

At the base of that hill.

I pass this motor everyday; saw the exhaust - Always wondered what lurked underneath that bonnet!

Sure know what your doing. Who's is the other Caddy parked up nowadays?

Rob.