I've done a fair bit of digging regarding the supposedly correct way of aligning the PD injectors in the head. General opinion was to just lob them in and be done with it but the official VW workshop instructions give precise measurements for the injector bodies which is measured from the outside RHS edge of the cylinder head.. 

 

This meant sourcing a suitably long vernier caliper which came today. 

 

 

 

The suggested tolerance is 0.8mm so these are as damned close as I can get them. They all sit now ever so slightly off square which is apparently how they're supposed to be. 

 

 

The retaining bolts (new genuine ones of course) have been torqued down to 12nm then 270degree tightened.

Rear beam has been collected today, as usual Bournes powder coating has done a lovely job.

 

 

 

They masked all the threads that I asked them to and it'll be much nicer once all the new bearings and stub axles are built up

13 minutes ago, Lofty said:

Rear beam has been collected today, as usual Bournes powder coating has done a lovely job.

 

 

 

They masked all the threads that I asked them to and it'll be much nicer once all the new bearings and stub axles are built up

 

Will be a shame to put that on! Looks awesome!

 

 

Got the air con pump fitted back up and loosely fitted the top engine mount.

 

 

 

Had a call from Camcoat, the tubular manifold and turbo housings are done and will be back here Saturday.

Strange thing not being able to sleep, it gives you lots of time to think things over. I had a aligned the injectors using the measurements used by VW taken off the outside edge of the head. Here's me at 4am thinking "what if the head castings are different thickness on the outer edge" and sure enough, the new head is 3.1mm thicker on the casting compared to the original 2005 head off the car, why? Who knows? But it meant my injectors were out of line, so I had to get a new set of injector hold down bolts, and do them again, adding on the 3.1mm..

 

Moral of the story, if it don't feel right, check check and double check. And drink tea at 4am...

 

Having rectified that possible mistake I refitted the injector rockers and using a dial gauge set the injector lash to the now required 180degree setting. Fitted the rocker cover, front fuel rail and cambelt cover for the last time.

 

 

 

 

 

The bottom pulley rubber cover came as well.

 

 

And of course, all this hard work is covered up by the engine cover...FML

 

 

New alternator needs to be sorted out and then I need to sort out the delivery balls up from Camcoat...

 

Currently in the office at work I have a very nicely ceramic coated Classic Lamborghini countach exhaust system and some bloke has my Fabia diesel parts.... 

 

i should get them by tuesday apparently....

 

Wicked motor mate just picked my 07 mk1 vrs up the other week looking to lower it and put some nice shoes on it soon and maybe a map. What fmic is that ?

3 hours ago, darren_vrs said:

Wicked motor mate just picked my 07 mk1 vrs up the other week looking to lower it and put some nice shoes on it soon and maybe a map. What fmic is that ?

The front mount that was on it was the Forge one. Not got to the point of sorting a front mount out for this build yet but have a feeling it'll be something bespoke 

Love this car u got it from the same place I got my mk2 I remember seeing it there lol 

Sneaky peak of the ceramic coated parts..

 

Exhaust housing done in gloss black

 

 

Turbo inlet compressor housing done in Ice Grey

 

 

 

And the tubular manifold done externally in Ice Grey and the insides done in a different gloss black, all in aid of keeping as much heat as possible inside the runners to speed up the gas flow, faster gas flow equals faster spooling turbo...

 

 

More pics when the turbo is reassembled 

Quick mock up..

 

 

 

 

 

need to source a GTB spec TIP which I suspect will be a dark side one. Once the turbo is mounted properly I'll also have to sort the oil drain for it, thinking of a proper Aeroquip braided pipe and AN fittings, just need to measure up carefully 

The build is epic ,time ,effort not to mention hard earned money ,will be one of the greats when finished top work .

Really is a work of art mate, I visit this thread to satisfy My OCD.

Cheers guys, ordered the GTB spec TIP this morning, along with the required 80mm silicon pipe work so I can run the standard air box. 

 

Looking at the crankcase breather next, I'm 100% keeping the engine cover so there will have to be some clever thinking to route the breather hoses out of the way

That engine is a work of art, outstanding mate. I need to up my standards on my build haha! 

Understand about the cover for oe look ,but needs to be left off to show it off 

25 minutes ago, rich9 said:

Understand about the cover for oe look ,but needs to be left off to show it off 

You big tart!!! It's all about knowing it's underneath lol... 

Spent a peaceful evening with a GTB turbo in the garage tonight, must credit a lot of the advice to the esteemed Fabia experts in our group chat for the set up advice.

 

Set the stop screw correctly, fitted the core to the exhaust housing with the sealing ring in place, then mounted the actuator. Set the actuator up with the vacuum pump so hopefully it'll be pretty **** on once it's running. The settings it was on it's a miracle it ran at all

 

Fitted it finally to the tubular manifold and fitted that to the engine.

 

 

 

 

Im not 100% on the accuracy of the inlet yet so that's only held in finger tight for now. Will check that another evening.

 

Exhaust and inlet manifolds will be final fitted soon then it's turbo oil feed and drain to sort out.

 

Love the attention to detail on this build, get excited whenever I get an update notification on it, can't wait to see it finished.

What an awesome project! I have just glossed through the 10 Pages but this is awesome, Absolutely leagues above what I am capable of doing.

 

Well done! 

^^now THAT is high praise Matt!!

I keep been distracted by the other daily Fabia that's sapping my attention and enthusiasm but I have been progressing albeit slowly. The black one needed new suspension and it made sense to take the ultra low mileage Bilstein B8 from the yellow one and fit that to it. 

 

The suspension had got to come one off the daffodil as I need to start the underneath resto in earnest so it's now sat in the garage with all four corners empty and just the rear beam, fuel tank and heat shields left on. I'll make a start prepping and painting in the next few weeks but the need to source new suspension has been satisfied by the arrival of these...

 

 

 

Bilstein B14 PSS coilover kit. Having run Bilstein dampers on the last 6 cars of mine I know the quality and performance of them is beyond reproach hence pulling the pin on these. 

 

Ill update more with pretty and not so pretty pictures of the car as we progress 

Exact same kit I fitted on mine, I wasn't disappointed with the ride qualify at all. 

Front legs built up using new strut top mounts and bearings. 

 

 

 

Had to order a cranked 22mm ring spanner so I can tighten the top mounts up properly but apart from that almost ready to go back on the car... eventually lol

What stuff did you use on engine to clean up then to paint etc

Used everything I could find! To get the grub and grime off the block I used Bilt Hamber Surfex, quite a strong mix, pressure washed off, then attacked the block with scrapers, wire brushes, scotch pads etc. The heavier rust actually chips off easy with a screwdriver and a small hammer.

 

Get as much crap off as you can then a few coats of Bilt Hamber hydrate 80 rust convertor then zinc primer etc