2 things

Fuel pump was knackered and not delivering anywhere near enough pressure which explained why it was wanting to start but failing so put a new S3 one in which got the car started

Wiring was a bit out as well.. the car started but had a dead pedal... once that was sorted the car wouldnt switch off

but after a bit of messing around its all sorted

So the todo list

Fix oil leaks

Add catch tank

Re-fit interior

Fit Gauges

Re-cut the slam panel as the current one looks like a bit of a mess

Buy a brake pedal switch and fit a new clip on the back of the brake pedal (pedal makes a weird clicking noise)

Add and bleed the coolant system

Pin in the EGT sensor

Get the car tracked

Run the engine in with mineral oil

Change for normal oil and send it for a remap

Edited 23 May, 201313 yr by no1naz

getting there dude =D

i'm like a proud father right now...seeing that car moving...BREATHTAKING! lol

Glad the wiring was sorted in the end, bit of a frankenstein wiring setup

Always had doubts about the fuel pump...so another thing sorted there nicely!

Crank side oil leak will be a bitch to sort unless its just a loose bolt that was overlooked, lets hope its sorted soon...i know you're itching to take this car out now.

Looks like u and Sanj have put a lot of work into this . Hope to see it a show soon . Good luck with it . Dave

Looks like u and Sanj have put a lot of work into this . Hope to see it a show soon . Good luck with it . Dave

Thanks mate... the effort gone in was crazy... i think we both underestimated how much work was required to make it work

I dont think it was helped by the fact that i kept pushing more onto Sanj like the big turbo and big brakes

but hopefully its not too long before its fully ready for the road :-D

This is Epic. A lot of inspiration for mine. Any update on this?

Keep going man, This is such an achievement!!

This is Epic. A lot of inspiration for mine. Any update on this?

How strange.. i was just about to comment on you are thread on uk-polos

i saw u had a problem with you are driveshafts... i measured one of my shafts and took a pic of its length.. when i find the pic il let u know

no updates for now

just waiting on the guy who did the rebuild to get some time to sort the crank oil leak and then i can solve the other leak and get this engine run in properly

I did start putting the interior back together tho

Haha that is a coincidence. Thanks for the help man. Will need all I can get

Naz...saw the thread on Tee's mk5...nice to see we may have given some inspiration on the subframe box mounting and i also noticed the crackle black powdercoat lol...nice build thread either way

...cant wait to see this thing sorted! :-D

Naz...saw the thread on Tee's mk5...nice to see we may have given some inspiration on the subframe box mounting and i also noticed the crackle black powdercoat lol...nice build thread either way

...cant wait to see this thing sorted! :-D

yeah including that build that makes maybe 5 1.8T builds almost done

I've hopefully got someone coming to fix the oil leaks in a week or so

and then i can make some more progress on this

Thats good news with the oil leaks! Can't wait too see what power this beat will make.

I just hope I can get mine mapped sensibly, not shooting for figures just driveability.

Thats good news with the oil leaks! Can't wait too see what power this beat will make.

I just hope I can get mine mapped sensibly, not shooting for figures just driveability.

As soon as i have the leaks fixed I'm going to book it in with R-tech, i hear the wait time is fairly long

But that will give me the opportunity to run in the engine and sort any more issues i find

I think I'm gonna go for maximum power on this

I'm hoping the stiff mounts combined with the stage 4 clutch and LSD should help with driveability

In theory it should work well

In reality tho... I'm not sure

Thats good news with the oil leaks! Can't wait too see what power this beat will make.

I just hope I can get mine mapped sensibly, not shooting for figures just driveability.

As soon as i have the leaks fixed I'm going to book it in with R-tech, i hear the wait time is fairly long

But that will give me the opportunity to run in the engine and sort any more issues i find

I think I'm gonna go for maximum power on this

I'm hoping the stiff mounts combined with the stage 4 clutch and LSD should help with driveability

In theory it should work well

In reality tho... I'm not sure

Yeah R-Tech are the place to go! Thats where I'm going to be taking mine, not sure on the waiting time though but i do know they will have it for a week or more.

HAHA! Its should help in theory

So had the crank oil seal changed, cambelt was an absolute mess

you can see the thin layer of oil all round the cambelt so fitted a new one

luckily we changed it without taking the engine out

also we identified the other oil leak and should be an easy fix

but we found a few other little problems, but nothing too major

so time to make some more progress

I'm currently buying in some parts so i can make one last push to get this car on the road

Catch tank was next on my list

I bought a generic ebay catch tank... pure rubbish

I then bought a Jaz products one which was a bit better but the outlets were not suitable for a 1.8T

I looked into the Saikou Michi catch tanks which ticks all the boxes but at £100 is a bit expensive

So i used that in mind to make my own

So I bought another generic catch tank and modified it

Picked it up from the powdercoaters today

I've been looking at catch tanks and like you say the only ones that are really suitable are exspensive. Think I'm going to make my own as I've literally just seen some nice aluminium tubing on our scrap rack at work

I've been looking at catch tanks and like you say the only ones that are really suitable are exspensive. Think I'm going to make my own as I've literally just seen some nice aluminium tubing on our scrap rack at work

The only thing good about the expensive ones is they have an inbuilt filter within the tank itself, but I'm venting to the atmosphere and am using two filters to do so

If you are running it back into the intake the expensive one is worth the money i think, the damage the breather system over time is worrying

But if you are doing what I'm doing then definitely make it urself... i made both of mine, added the correct inlet/outlets and powdercated them for under £100

I've been looking at catch tanks and like you say the only ones that are really suitable are exspensive. Think I'm going to make my own as I've literally just seen some nice aluminium tubing on our scrap rack at work

The only thing good about the expensive ones is they have an inbuilt filter within the tank itself, but I'm venting to the atmosphere and am using two filters to do so

If you are running it back into the intake the expensive one is worth the money i think, the damage the breather system over time is worrying

But if you are doing what I'm doing then definitely make it urself... i made both of mine, added the correct inlet/outlets and powdercated them for under £100

Yeah think thats the best way to go, I'm going to vent to atmosphere too. All i need is some weld on ali fittings and mines done!

Haven’t updated this in a while, but have been pretty busy on this

So started by identifying the last remaining oil leak, Turned out to be one of the outlets for the oil temp/pressure sensors
We tried some PTFE tape to create a seal, this only reduced the amount leaking
I was about to buy a whole new unit when i was recommended some Loctite which creates a seal around the thread. This seems to have stopped the leak completely
So will keep an eye on it just to make sure the leak doesn’t re-appear

I then started looking into the clamps that were given to me by simply supreme when my intercooler work was done. They gave me some Mikalor ones which have very mixed reviews on the internet.
After some research I paid SFSPerformance in Luton a visit and bought some Murray clamps. They gave me a very good price on them so picked up a bag of them. I would recommend them to anyone who is looking for quality clamps or silicone hosing



Here is a comparison against the Mikalor ones. The Murray ones look alot better in my opinion and apparently are much better functionally

Next was to sort the broken Powerflex anti-roll bar bush. All Powerflex products have lifetime warranties on them. A simple call and some new ones were sent over
The old bush looked like it may hold but I didn’t want to take any chances




Once removed you could see some considerable damage to it, I’m happy I had it replaced



As far as I could tell car was ready for a start
I was planning on getting the car properly up to temperature so filled it up with water to test it.
As I the water filled, I noticed some water was dripping onto the floor.
The leak was coming from the turbo water line. I removed it to find this



Went and visited a local hydraulics company, Hopespare who made me a new line for £30



So started the car this weekend and finally had a car with no leaks
Car idled and came up to temperature fine

So my to do list, in order

Send car to bodyshop and have aerocatch's fitted to bonnet and front bumper modified to accomodate the intercooler
Fit brake pedal clip and switch and test it
Fit catch tank
Re-fit interior (half done)
Add and bleed the coolant system
Buy wider Porsche adapters
Get the car tracked
Test fans

Pin in the EGT sensor

Fit Gauges

Run the engine in with mineral oil
Send it for a remap

Good progress

Nice one man! Almost there

So went to test the fans on the car which meant running the car for a long period of time
Checked over the fluids in the car when i noticed the power steering was low so topped it up
When the car was started we noticed the power steering pump was leaking

Removed the pump to find this



The original polo pulley was not shallow enough to use so we replaced it with a 1.8 T golf pulley, but it seems to be too shallow
So replaced the pump and spaced the pulley out by a few mm's
Seems to run fine now

Then moved back onto the fans and more bad news, fans did not kick in at the right temp
Measuring blocks on vagcom had the temp of the engine at 106 degrees but the dash had the temp at 90
Both should be getting the engine temperature from the same sensor so not sure why there is a difference

Car is going to the bodyshop now to have front bumper and aerocatches fitted
Have spoken to James at OBD works who will look into the problem with the fans, pin in the EGT and wire in my gauges
Will book it in when the car is back from the bodyshop

Hoping to have the car ready for the road this month

Here is how its currently sat.. slowly coming together

Edited 13 November, 201312 yr by no1naz

Stunning project.

great thread fair play to you :)