that's amazing, i love this car mate! great stuff :)

Holy shit! This is by far one of the best reads! Love it! Would love to see it in person!!!!

Olly...what a read mate!! cheers for the detailed pics, as usual...i expected great work and thats what you've photographed!

Maybe in the future i'll give this a blast on one of my cars. :-D

credit to you

top stuff

whats the ride like on air?

fucking top work mate, hat off to u

how much did the r32 front and rear bumpers cost you?

top stuff olly. really is a serioulsy nice car now bud. the air is just the icing on the cake. wouldnt change a thing really, everything is spot on!

oh and you have definitely convinced me to upgrade my air to digital management. really does look the business!

keep the updates coming bud

thanks for all the kind words fellas, been a while since i updated this thread due to buying the mk1 jetta and then an S3 but decided to sell the s3 a couple of weeks back and started messing with the bora again....

i decided to re do the air install in the boot - at the time i had no idea how big the task ahead would be.

as i now have a second car i decided i can live without a spare wheel, so i removed the bits from the well and tried to get a mock up of how it was going to be laid given the large (long) tank

it was either as above or the tank straight down the middle - it just wouldn't fit any other way, so i made a floor for the well from 12mm MDF

when i placed the tank ontop it sat too tall due to the well sloping up to the rear of the car so i had to cut the floor down just to cover the level part.

i decided the tank should go straight down the middle and i'd get another compressor to fit on the other side of the tank so i mocked it up

drilled holes to mount the compressors and tank and counter sank them to sit flush

now that had been decided i needed to make a wall to go around the curved part, after looking at a few options i decided to go with 3mm MDF but double it up to make it more rigid

once dried i fitted the tank and tried it in the well

next was to knock up a section the other end, i wanted a part i could display my E-level ECU and make it look a bit more pretty

first i knocked up a wall the tank could pass through

the from there i made a raised section of floor to account for the sloping wheel well and a box either side to display bits (batteries died in the camera so no real in between pics)

i'd cut out a section on the right to mount the ecu but on the left all i had was my remote receiver. now i could see with just the tank and two compressors it was going to look a little empty.

i decided to ditch the flexi pipe and the compressor braided pipe and go for hard lines in 10mm copper, i thought i could fill the space better with the hard lines so i had a mess around

now i had to match it for the other side

i was going to run the pressure shut off switch in the spare port on the side of the tank but thought it'd look better if i ran a pipe into the space under the left box

with most things set where they were going to go i finished the sides to the box and screwed it all together

also put some more dynamat down in the well

and tried the box again

once i had it fitting in the wheel well right and changed the box wall thickness it was time to cover the inside. carpet and leather trim had crossed my mind but i thought i'd have a go at flocking - i bought 2 x kits from Frost, these turned out to be pretty rubbish but it's all a learning curve.

i applied the adhesive as instructed and puffed the flock on with the absolutely useless bottle that was supplied, trouble was it took so long to get it puffing out of the bottle the MDF was absorbing the adhesive.

i redid it but is far from perfect but i can live with it, i did the right hand box but left the left as i was undecided what i was going to do with it

i started to mount it all up again

also decided to paint the hard lines candy white to contrast a little

now with the indecision and currently fairly empty left hand side box i thought for looks purpose only i'd install a VIAIR illuminated pressure guage. i thought seeing as i had the pipe run into there for the pressure shut off switch i'd tap into that.

so i cut a hole of where i wanted to mount the dial

and screwed the remote receiver down to get a feel for it

next was the fun part, connecting the original pipe i'd run to go to the guage - not only that but i had to T into the line for the pressure switch and with very limited space this was not fun!

then was the next problem, the sensor + adaptor brought the sensor out of the box and would hit the wheel well so i removed the T and chopped it down, redrilled it and cut a 1/8 BSP thread into it and re threaded the sensor to the same and to lose the taper so i could get it in further to increase clearance

so refitted it in place

once i'd got it all spot on and tightened down the guage sat flush in the cut out, now that was set i removed it all again and flocked the last bit (still wet in the pic)

...and refitted it again

just waiting for the other compressor to arrive then i can get it bolted in and hook up the electrics and start to make a cover.

the second compressor hasn't yet arrived so decided to start knocking up the cover

drew around the carpet to get my rough outline

cut it out trimming here and there to get it to fit snugly

once that fitted in it came to the tricky part - working out where exacly the holes needed to be in relation to the bits underneath (along with deciding what shape and how big they'd be)

after much adjustments and mad scribbles i've ended up with this

as you can see i'd also fitted some LED strips as backlights, i'm quite happy with them - i think they'll look better when the cover is finished off.

i think they work much better at night though.....

still need to trim the cover and fit some perspex in the cut-outs to keep it free from dust

this is obviously hugely summerised and doesn't include all the dramas ordering fittings (incorrectly) and waiting on parts etc etc

been a looong job so far and it's the first time i've done a boot install type thing so don't be too harsh if it's not 100%

Edited 2 December, 201015 yr by polo6n2g40

i love your work dude and the car looks amazing...

Dimz

I'm a truly envious of your skills mate.

I love the 'knocked up this..' And it looks perfect! Big fan mate.

You made me buy one as soon as I saw this!!

Answer you are phone Olly man! haha

Installs amazing, cant wait to see it all finished and working!

everytime i read your thread it really does make me feel bad about the progression of my car!

going to have to ask couple of questions about this accuair stuff. it looks the business!

Edited 2 December, 201015 yr by wellse6n2

I love this car so much and I really envy your skills! Sits perfectly and the air install is so bang tidy!

I owe you a drink at the next show too for the dashboard guide, was very helpful!

stunning work.

another awesome update fella!

them lights on the tank and workings looks awsome, good work pal!!

question though, how much was that dynomat and where did u get it from?? I've stripped and borded the back out of my polo but the road noise is really annoying i really need some!.

cheers

Oli :)

Edited 2 December, 201015 yr by mintwiththehole2

OMG that is just awesome !!!!

I am so jealous of you, cant wait too see this next year at a couple of shows and actually bask in your awesomeness!!!!!!!!!!

Edited 2 December, 201015 yr by seanvw

Nice work, I've used those "flocking kits" before from frost... yours came out alot better than mine! haha, I helped my mate flock some interior parts, we both lost our temper with it several times.

bask in your awesomeness!!!!!!!!!!

:nod: