what are the discs off? there not normal vw discs as they have a large height between the disc and the wheel mounting face. they honda?

if its fouling on the ball joint then they will need changing as you cant space them out like wheels - you may have to run wheel spacers to give you clearance once you fit them

what are the discs off? there not normal vw discs as they have a large height between the disc and the wheel mounting face. they honda?

if its fouling on the ball joint then they will need changing as you cant space them out like wheels - you may have to run wheel spacers to give you clearance once you fit them

I'm so glad you've commented, they do foul the ball joint and i can only imagine it must be because they've supplied the wrong discs ? I'm giving rally designs a ring in the morning to see what they say..

I dont think its a case of wrong discs etc...i think this setup is for cars that use a similar brake setup as the Ibiza Cupra.

I have a set of 305mm discs and brembo's with appropriate brackets (mk2 golf hub fitment)- these also foul on the ball joint as i found out yesterday.

The only way around it is by using different discs and a different caliper carrier bracket- one that spaces the caliper out along with the disc.

If willwood provided you this setup as a kit- then what is the kit supposed to be used for- universal fitment or mk4 platform cars- golf mk4, seat ibiza etc...

Because i think an earlier mk2 golf/corrado setup would be a better fit and if it is...let me us know as i'm in the same boat as you. :-D

Pic of the disc hitting the ball joint, and the disc from the front:

Edited 17 June, 201214 yr by DubbPrince

I dont think its a case of wrong discs etc...i think this setup is for cars that use a similar brake setup as the Ibiza Cupra.

I have a set of 305mm discs and brembo's with appropriate brackets (mk2 golf hub fitment)- these also foul on the ball joint as i found out yesterday.

The only way around it is by using different discs and a different caliper carrier bracket- one that spaces the caliper out along with the disc.

If willwood provided you this setup as a kit- then what is the kit supposed to be used for- universal fitment or mk4 platform cars- golf mk4, seat ibiza etc...

Because i think an earlier mk2 golf/corrado setup would be a better fit and if it is...let me us know as i'm in the same boat as you. :-D

the kit I've bought was meant to be for a mk2 golf, but as you say,looks as though the only way round making them fit is spacing out the caliper and using another disc.

the only problem is, I'm lead to believe the wilwood calipers can only use a certain width disc

Have you messaged panda as hes running wilwoods on his 6n

the kit I've bought was meant to be for a mk2 golf, but as you say,looks as though the only way round making them fit is spacing out the caliper and using another disc.

the only problem is, I'm lead to believe the wilwood calipers can only use a certain width disc

Josh,

if thats the case then we can both be sure that ibiza/mk2 golf hubs are different to polo hubs and the kit you want from willwood then is for a Lupo/Polo GTI instead- see what they say.

the kit I've bought was meant to be for a mk2 golf, but as you say,looks as though the only way round making them fit is spacing out the caliper and using another disc.

the only problem is, I'm lead to believe the wilwood calipers can only use a certain width disc

Josh,

if thats the case then we can both be sure that ibiza/mk2 golf hubs are different to polo hubs and the kit you want from willwood then is for a Lupo/Polo GTI instead- see what they say.

just been in touch with rally designs, they say that the kit they prvided is for a mk2 gti, whereas the kit i need would be for the early G60, as these have a lower offset disc and smaller thickness, which means i will need a differant caliper and caliper spacers to accomodate the offset and thinner disc.

@POLOMON - it is exactly the same as the above picture from DubbPrince, only just fouling the balloint but also a possibility of fouling the steering knuckle :/

what balljoint would you recomend, I'm willing to try anything before returning the whole kit to rally designs

There are no other different ball joints mate, its all about the hub itself where the ball joint attachs...the later mk2's must have a ball joint that bolts further towards the wishbone than the hub.

Makes sense if RD have said early G60 as i was wondering why G60 brakes fit perfectly fine on polo's like my own.

The only way around this is to get ball joint extenders to push the ball joint further down-

But for the cost and effort (no idea how much clearance they would give for your disc size)- they are also used on vehicles wishing to go static low to straighten the geometry of the wishbones...you might as well return the willwoods, order the early G60 setup...or ask if you can return just discs and brackets and get the correct bits...job done.

keep us posted.

thought about using ball joint extenders, but for the money they cost i can get my old calipers and discs returned and a new setup sent to me.

I've done a little research and found that a few of the mk2 boys with the wilwoods flip over the mounting braket I've been given, as this gives more offset on the caliper, they then use a mk1 caliper with a G60 width disc, they have to use the mk1 caliper as they a a narrower fitment for the disc.

only issue with this is that the caliper may foul my wheels now, so a possibility i may need to space them out, or buy new ones.

I'm packaging my stuff up today and should recieve the new kit friday ready to fit for the weekend (fingers crossed)

step mum just text me to say my brakes have been delivered (although they were meant to come to my work address)

all being well the weather will be decent or atleast it wont be raining tomorrow, and ill get them fitted, ill update if the problem is sorted :)

brakes are on fine, need to space my wheels out now to clear the caliper 13mm should do it...

looking for a rear ARB, so if anyone has any info of what fits or has one for sale let me know !

any chance this can get moved to the MK4 section ? feel like it might get a few more views and comments in there

little update on brake line routing even though this is old now and its all done

this happened this weekend

also got some braided power steering hoses made up, haven't got pictures because they arent really worth taking pics of haahaa

bought some wire for the battery relocation and started plugging stuff in, might have a go at turning it over tonight, and maybe even try and start it

Can you get a snap or two of your engine mounts dude? You using standard mounts yeah, unmodified chassis legs etc?

welded a plate to the N/S chassis leg and used a 9n3 tdi engine mount on a 9n3 gti gearbox (02R)

the offside mount is a vibratechnics mount for a MK2 mounted to a custom plate made to fit the existing mounting point.

ill get pics if i can dude

Nice one dude!

them brakes are beautiful, wish i had the engine to justify getting a set

you dont need a fast car for nice brakes

this doesnt even move yet hahaaa

hooked the battery up tonight to turn it over, windows went down and no lights came up on the dash at all, interior light came on too, but that may be just because the door was open.

any ideas boys ?

hooked the battery up tonight to turn it over, windows went down and no lights came up on the dash at all, interior light came on too, but that may be just because the door was open.

any ideas boys ?

I take it your battery is fully charged? and the engine has previously been started? (in the 6n shell once you moved everything from the 6n2) because you may have missed a connection somewhere.

Edited 13 July, 201214 yr by DubbPrince

yeah the battery is fully charged, not had it started yet, this was gonna be my first attempt

think it could be the earth to the dash, had a look in the technical forums on edition and someone has had the same problem, ill investigate tonight !

so close to being done now ! need som3e 15mm hubcentric spacers if anyone reading this has any ? PM me

Edited 13 July, 201214 yr by Josh16v

Amazing work mate :) looking forward to seeing this done!

And to do with the dash lights issue, have you double checked all the connections from adapting it into the 6n loom?

boom ! dash lights are on !, think the window issue is because my door looms are 6n and the interior loom is 6n2

still wont turn over from the key though, like i say, all dash lights work but on a full turn of the key, nothing.

starters fine cos I've had it off and tested it, and will turn over if i put a live straight to it, just wont crank from the key .....

help me ?

boom ! dash lights are on !, think the window issue is because my door looms are 6n and the interior loom is 6n2

still wont turn over from the key though, like i say, all dash lights work but on a full turn of the key, nothing.

starters fine cos I've had it off and tested it, and will turn over if i put a live straight to it, just wont crank from the key .....

help me ?

Hard to tell where to start mate, why dont you give us a run down of the loom itself...guessing it was already created to plug and play? so you should have a thick red live coming in from the battery fusebox? and all connectors are on at the fusebox (coloured plugs)...the dash wiring picks up the earth from the centre tunnel and to either side of the shell inside beside the footwell...there should be a thick earth cable coming off the gearbox or near there to the earth point on the passenger chassis leg...

Lastly the ECU is de-immobilised so should start without checking the clocks...just go over every connection you made and make sure everything is still in place.

if you have ignition, then maybe try vag com on the diagnostic port to see if theres another issue.

Check all fuses and relays are working too.

can finally get it to turn over from the key, the plug from the starter to the ignition relay was a dud, ran a wire outside the car to the starter a voila the starter cranks

problem is now, its as though the live is in the wrong way round...

turn key - so first position, starter goes but doesnt disengage

second position (where starter should engage) starter disengageds and nothing happens..

if you get me?

bought a new ignition switch from work just incase its the old one being faulty, also had a look through a haynes manual i have and it says only the auto 6n2's should have this ignition relay, so might just bypass it all together

anyone got any other ideas ?

I'm not sure what you mean above but I have a similar problem where I turn the ignition to Point 1 and the starter fires straight away so there actually is no Point 1, it skips straight to point 2 and fires the engine.

Damn 20v wiring!!