Lofty's Sprint Yellow Fabia vRS Mk1 - "Project Daffodil"

[hutchysrs50]

I thought crackle black also, that's why I had to ask.

It would look awful :D glad it's staying silver, just kept my opinion quiet until I knew! :p

[coskev]

I thought crackle black also, that's why I had to ask.

It would look awful :D glad it's staying silver, just kept my opinion quiet until I knew! :p

Craple black :O

[Lofty]

Haters gonna hate.

The inlet, EGR and anti shudder valve have all been painted and are drying indoors now.

I'll get some pics up soon, just to keep Kevlaar happy they've been finished in OE silver.

Pricing up some options on ceramic coating the tubular exhaust manifold, my preferred option is the zircotec motorsport white finish but it's nigh on double the cost of the camcoat black coating..

[coskev]

They are totally different types of ceramic coating though,hence the price difference ;)

[chris-H]

Loving following this build, keep the updates flowing please. Keeps me feeling positive especially after a weekend when ahem, I've just been told my gearbox is fubared!

[Graffiti]

This thread has blown me away!

 

I have had mine off the road upgrading turbo and Fmic, cleaning and servicing etc put it all back together and am delighted with myself!  But read this thread and well, you would start twitching if you saw it lol  

 

Seriously though, you must have been eating, drinking and sleeping this car!   What an accomplishment.   Well done pal!

[Lofty]

Cheers guys, it's turning into a labour of love but enjoyable all the same.

So, update time. As you know I want to retain the kind of stock look under the bonnet but with choice modifications where needed, so with a desire to retain the anti shudder valve and EGR I had to locate some, as the ones previously on the engine now live on the black one outside, so I bought a BLT spec EGR and ASV off eGay.

This is them in all their questionable glory...

 

 

 

 

 

Mmmm lovely.

The insides were as dirty as the mind of an inbred...

 

So various tools and fluids were used to attack them clean

 

 

 

They have now been painted and the inlet looks like this..

 

 

 

New genuine rubber seals were sourced from TPS to ensure no leaks.

However the inlet is far from finished. You'll see that I have refitted the devils own water meth nozzle into the inlet where it came from. This is where the fun starts. The black car this inlet came from was the jabba stage 3 thing, so it ran a much different turbo to the conventionally mounted ones so this nozzle will now foul the TIP. Bugger.

Plan is to modify the internals of the EGR to mount the meth nozzle underneath it. I'll show you what I'm doing as I go along..

Edited 29 March, 2021 by Lofty

[skodalad]

Nice to see everything being kept OEM mate, I know how much patience it takes.

 

Look forward to seeing how you remount the nozzle into the egr

[Lofty]

The EGR mods are continuing.

Starting with the normal inards

 

 

 

I took various cutting implements to the piston itself, then ground down the neck of the piston and also the large ramp at the bottom where the piston seats. The aim is to reduce the thickness of the material at the base where the hole is, as that's where the meth injector needs to be pointed upwards into the airstream.

 

 

 

 

The EGR blanking plate will be drilled and tapped to take the nozzle and hopefully it'll be deep enough just to be flush with the base of the EGR "floor". If not I'll have to take some more material out of the floor itself.

Hope this makes sense? It'll all become apparent when the bits are together

Edited 29 March, 2021 by Lofty

[Lofty]

Bit of frustration at the minute. Bottom end of the engine build had started but quickly stopped again when the rod bearings were found to have been supplied wrong. My own fault for not checking them before.

Pistons have been built up onto the rods, rings oiled and the gaps staggered 60 degrees from each other then using the piston ring compressor we fitted them into the right bores. Thanks for the heads up from Adam regarding the oil spray jet alignment.

Pistons and rods in.

 

 

 

See how the notch in the piston corresponds with the space for the oil spray jet. There's enough adjustment on the spray jets themselves to ensure that the oil goes directly into the holes in the underneath of the piston.

 

 

So until I get the rod bearings that's as far as I've got.

Brighter news came in the form of the brass bung for the inlet where the meth injector had been removed from..

 

The new Devilsown meth injector is here, it's their D05 nozzle which is rated to the required amount of boost/rpm etc

 

 

Next job is tapping the EGR plate and then taking more material from the base of the EGR valve so that the nozzle sits flush with the inside face of the EGR

Edited 29 March, 2021 by Lofty

[pip_vrs]

Good work

[skodalad]

Brilliant progress mate, unforeseen problems always seam to crop up when your deep into a build haha

[faboka vrs]

Loving how the water injection will be out of sight

Edited 14 January, 2017 by faboka vrs

[kellaway86]

Nice work lofty, few and far between who enjoy doing the job properly. I'm thinking about steeling your idea for my BLT egr, how ever not running meth but for hiding a boost gauge sender. By removing the piston and the excess metal and blanking off makes a nice stealthy egr delete. You going to be runing a fake vacume hose to it? How are you planning on sealing the piston to accuator off? Could see it possibly leeking and loosing boost out the accuator.

Edited 15 January, 2017 by kellaway86

[Lofty]

I'll still have the vacuum hose connected to it will have a blank in it

Hopefully get the rod bearings sorted tomorrow

To actuate the EGR piston takes one hell of a vacuum to operate it so I'm confident the boost pressure going past it won't force the piston open. I may well get it TIG welded over, not 100% decided yet

Edited 15 January, 2017 by Lofty

[coskev]

Supplied you with the wrong size bearings?

Good job you didn't have them ceramic coated! (Hope Alexs are the correct size :O )

[alex_e3]

Hence, my unanswered question in the group chat!!  :peek:

[coskev]

Hence, my unanswered question in the group chat!!  :peek:

I think grumpy Matt is sulking about the bearings :O

[Lofty]

Lol, my bearings didn't come from Alex's source... he'll be spot on I expect

[Lofty]

Finally the inlet is finished.

Drilled and tapped the EGR blanking plate. Fitted the nozzle in with a dab of loctite for good measure.

 

 

Had to take another load of material from the base of the inside of the EGR.

 

 

And all fitted up

 

 

 

 

 

Tomorrow night I'm gonna start looking at the exhaust manifold set up..

Edited 29 March, 2021 by Lofty

[Lofty]

Forgot to add, the red meth pipe will be changed for an install of black pipe which will be gently heated and curved to sit nice behind the back of the ASV.

It'll then be run behind the vacuum box and through into the inner wing area out of sight

[Lofty]

Finally got round to collecting the correct big end bearings from the suppliers and this is what they look like. The VW PD engine uses sputter bearings for the big ends. Essentially the sputter coating is the darker of the two bearings you see here. They go into the thrust side of the rod, i.e. In the rod itself, the lighter bearings go in the rod cap.

 

 

So we fitted the main bearings in..

 

 

 

Then the upper big end ones, lowered the crankshaft in and then slid the new thrust washers into place.

 

 

 

 

All the mains caps were fitted, the con rod caps were fitted along with the ARP rod bolts fitted using the correct ARP fastener lube and torque setting.

I wanted to check the main bearings clearance just for my own morbid curiosity and to ensure everything was in limits, so I sourced a plastigague kit and used it on one mains cap.

The suggested clearances are as follows...

Brand new crank and bearings, between 0.03 and 0.08mm with the west limit at 0.17mm

Mine are this

 

 

 

 

0.05mm so bang in line with what they should be.

Oil pump had been stripped and checked earlier and it was perfect so I fitted a new genuine oil pump sprocket, chain, tensioner and pick up strainer pipe..

 

 

 

 

 

New genuine VW rear main seal was fitted along with a new VW front main seal as well.

 

 

New sump was fitted and all sealed and torqued down to spec

 

 

 

(Running out of room and energy at this point lol)

So this is how it stands tonight.

 

 

 

Next jobs are oil filter housing and oil cooler fitment, fit the head stud conversion and measure up for the head gasket thickness

Edited 29 March, 2021 by Lofty

[R1chard]

Epic! Love this build

[coskev]

Looks like Jeremy Beadles hand holding that oil pick up pipe! :D

[skodalad]

Never fails to disappoint. Awesome work mate!