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Old 03-04-2018, 11:08 PM   #481
DocWalt
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Join Date: Feb 2009
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'92 GTI, '19 MX-5

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Current mod list, I think...

-abt shift knob
-conrero shift boot
-recaro sr-d (driver's) & lx-b (passenger's) seats on wedge engineering sliders
-audi tt pedal covers
-smoked time delay overhead cabin light
-AEM UEGO wideband
-VDO oil pressure gauge
-custom headliner (unfortunately glue has failed and it's sagging again...)
-momo door sills
-kenwood head unit
-infinity speakers in doors
-KW V1 coilovers
-K-Sport front camber plates
-ST suspensions swaybars front & rear
-Mk4 aluminum rear calipers with Carbotech 1521 (bobcat) pads & new rotors w/ new bearings
-new rear beam bushings
-new load sensing proportioning valve
-Techtonics Tuning 2.25" stainless exhaust with Borla muffler
-new high flow cat (Passat model has same exterior dimensions, higher flow core)
-Supersprint stainless tri-Y header
-braided stainless brake caliper hoses front & rear
-10.1" front big brake kit from Mk3, Pagid street pads & new rotors
-22mm master cylinder (I'd recommend upgrading to Audi Coupe Quattro 20V non-ABS master, ~25mm bore, for stiffer pedal)
-new brake booster in 2015
-new inner & outer tie rods
-new Mk3 power steering pump
-EAA "racing" braided stainless high pressure P/S line
-new OEM P/S pump feed line
-new ball joints
-lower control arms have new OEM front bushings & new R32 bushings (solid rubber instead of perforated) in rear position
-new OEM rear motor mount & transmission mount
-solid front motor mount
-new Hella H4 headlights with Hella 80/100w H4 bulbs
-custom headlight relay harness to handle VERY high wattage lights if desired (feeds battery voltage to lights for much brighter headlights and protects the headlight switch contacts)
-inner high beam lights have standard 55w bulbs
-new replica foglights (these are fairly worthless as lights, I was going to eventually replace them with brake ducts)
-Hella half-smoke taillights
-rebuilt 2Y 020 transmission with Peloquin brand LSD & TDI 5th gear (longer for better highway MPG). When cold sometimes 2nd gear grabs on the 1-2 shift and pulls the stick into gear, no clue why.
-Mk3 weighted shift rod (smooths out shifts)
-short shifter
-16V clutch
-new TDI starter (short snout so no support bearing in the engine block required) with Bosch WR-1 relay harness (ignition switch triggers relay instead of starter, ignition switch contacts don't burn up)
-new Bosch battery
-megasquirt 2 ECU (v3.57 PCB with various internal modifications) with custom harness using stock distributor hall sensor
-new 16V distributor
-flow tested/cleaned Bosch VW G60 injectors (265 CC @ 3 bar)
-3.5 bar fuel pressure regulator
-OBX fuel rail with stock o-rings replaced with fluorosilicone o-rings
-euro-spec 50mm big bore intake manifold
-ABD big bore intake tube
-custom airbox to fit OEM size air filter (has K&N panel air filter)
-NGK 1 step colder spark plugs
-NGP 16V spark plug wires
-new OEM VW coolant bubble (reservoir/swirlpot/level sensor)
-new radiator in 2015
-non-A/C alternator & belt setup (greatly simplifies the system to just two belts)
-new timing belt & tensioner pulley
-lightened/balanced intermediate shaft with new OEM bearings
-custom Setrab/Mocal thermostatic oil cooler setup replaced the stock heat exchanger
-all new coolant hoses
-new OEM water pump
-metal thermostat housing
-metal outlet flange off head (the aftermarket plastic ones warp and leak)
-Techtonics Tuning baffled oil pan
-ABA style rear main seal (teflon impregnated felt instead of a rubber seal, much less leak prone)
-standard 9A block with internal modifications to support usage of larger crankshafts
-forged TDI crankshaft (95.5mm stroke versus 92.8mm stock) that has been cut to one size smaller on rods & mains
-stock 16V rods with new rod bushings
-Eurospec Sport cast pistons for 83mm bore with offset wrist pin hole to allow for stroker, these have been modified with deeper valve reliefs. ends up at about stock compression figures (VW claims 10.8:1)
-OEM spec 83mm bore piston rings (stock bore is 82.5mm)
-King Race main bearings, VW motorsports style rod bearings
-high flow oil pump from Mk4 1.8t engine using a 16V pickup tube
-ported and polished head with 3 angle valve job
-high flow bronze valve guides (tapered tips) with viton valve stem seals
-supertech & ferrea valves with undercut stems and 0.5mm oversized heads
-Techtonics Tuning 288 race camshafts
-Techtonics Tuning HD valve springs
-OEM TDI hydraulic lifters (each is ~10g lighter than stock lifter)
-new OEM cam chain (drives intake camshaft off of exhaust camshaft)
-15x7 ET35 Avid.1 AV-08 wheels with brand new (like 2000 miles old right now) Kuhmo PA31 tires

Optional:
-15x7 ET35 Enkei RPF1 wheels with RE-71R tires
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Old 03-06-2018, 09:44 AM   #482
PAdutch
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Miata, Miata, Genesis, 08 burb 2500

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Thats a long list...
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Old 03-06-2018, 10:36 AM   #483
DocWalt
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Quote:
Originally Posted by PAdutch View Post
Thats a long list...
Yeah, don't even ask the costs... The engine that's in there is something like $7k in parts and labor, for example.
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Old 03-06-2018, 02:31 PM   #484
DaveSTi
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Quote:
Originally Posted by DocWalt View Post
lol, unsure if serious

semi-related, I redid the starting system this year. It refused to even crank over when below 20 degrees. Cranks over down below 0 degrees now New TDI starter motor ($$$!!!) and new big f'ing Bosch battery and new wiring to stop the ignition switch from taking the load of directly triggering the starter, it just drives a relay now.
I'm definitely tempted by the car. I absolutely miss having the GTI I had (and the 911 too) and would kill for another one. The hurdle would be cost as well as VW's new reputation for gassing monkeys. The latter has caused my wife to completely ban a VW from our driveway.

....but a used mk2.....
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Old 03-06-2018, 08:30 PM   #485
DocWalt
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This used Mk2 pollutes more than any modern VW lol. It idles at ~12.8 AFR, any leaner and it starts misfiring, lol. Smells kinda crappy (pretty sure I've slowly poisoned the cat with zinc in the oil over the past ~3 years)
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Old 07-15-2018, 05:50 PM   #486
DocWalt
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Took a couple of fun runs during lunch at Philly SCCA's Intermediate driving school yesterday:

http://www.youtube.com/watch?v=yiHWUx63KGE
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Old 07-15-2018, 07:26 PM   #487
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Originally Posted by DocWalt View Post
This used Mk2 pollutes more than any modern VW lol. It idles at ~12.8 AFR, any leaner and it starts misfiring, lol. Smells kinda crappy (pretty sure I've slowly poisoned the cat with zinc in the oil over the past ~3 years)


that smell is called nostalgia!
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Old 07-15-2018, 07:27 PM   #488
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Took a couple of fun runs during lunch at Philly SCCA's Intermediate driving school yesterday:

http://www.youtube.com/watch?v=yiHWUx63KGE
you were flying
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Old 07-15-2018, 09:52 PM   #489
DocWalt
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Quote:
Originally Posted by DaveSTi View Post


that smell is called nostalgia!
I'm glad I never lived through the "stinky car" era... and I'm glad I missed the malaise era. We've had such a great selection of performance cars since the late 80s.

Quote:
Originally Posted by DaveSTi View Post
you were flying
The car's still got it. I kinda want to do more... On course it can likely end up putting down similar times to the FoRS, very course dependent though.

I pulled 5 degrees of timing before the event just to ease the stress on it due to ping with the hot ambient temps recently. It was noticeably less peppy in the low-mid range. I might start feeding it some timing and seeing if it responds well with no pinging.

Last edited by DocWalt; 07-15-2018 at 09:55 PM.
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Old 03-11-2019, 10:20 PM   #490
DocWalt
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Replaced the shagged sunroof seal a week or so ago:



Fluffy new seal!





Took the header out for some maintenance involving the spring bolts (that no longer had functional springs) and one broke, so out the header came. I discovered it had a small leak so I addressed that issue too. New springs & bolts arriving soon! I actually got the bolts but the springs I ordered were nowhere near stiff enough.



My intake manifold needs to be powdercoated or nicely painted.
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Old 03-12-2019, 09:18 AM   #491
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Love this car
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