george_seamons

Need something made along the lines of the attached picture (although only the top half mirrored really). Needs to be beaded both ends, one end 63mm, the other end 40mm. Basically to join 2 boost pipes. Each end needs to be big enough for the bead, and a jubilee clip...so probably about 25mm (50mm ish total length). Andybody game?

Haha yes, it will be cleaned (although not by me...its not mine ). It's pretty grim though, the whole car is looking a bit sorry for itself!

Thank you to all those that have donated so far, really means a lot, and is a decent push towards the target

Might even be done by then!

Just on a stock PD130 turbo for now, then give it a bit of ashake down to check its all pukka. Once its done a few thousand (and the owner has saved up the money), the new turbo, the diesel gearbox internals, and the new intake) can all go on when the engine is back out

Good day Saturday on the TTTdi. Had to go bedroom furniture shopping (yawn) on the Sunday, but still managed to sneak a couple of hours in afterwards. There are some big gaps in the timeline of pictures because I got so involved I forgot to take any haha! Started off with lining up the engine with all the bolted up new bits ready to go in the bay: Engine in and bolted up with new bolts and mounts etc. Propshaft connected to transfer box, clutch line plumbed in, coolant lines etc piped up, chucked the coolant radiator and a/c radiator on, ready to fit the front panel: Then mounted the front panel, which supports the coolant radiator and a/c radiator: Then chucked the crash bar and headlights on: Chucked the engine cover on to see how it looked: The petrol fuel lines were then pulled out, and the diesel ones put in place, along with the fuel cooler, which sits under the drivers seat on the bottom of the car: Next up was the diesel fuel filter housing and bracket. Obviously the TT doesn't have this as stock, so needed to be drilled and mounted, as per the Golf. Fuel filter pipe up and resting in position ready for the bracket: Marking the holes ready to be drilled: Holes drilled, bolts tightened, and bracket mounted: Fuel filter housing sitting in its new home, looking like stock: Then the coolant expansion bottle was fitted (this will be replaced with a new clean one once the engine is ready to be filled with coolant): I then fitted the stock strut brace in place, and offered the engine cover up to see what it looked like. Needed a bit of trimming to get it to sit properly (the Golf doesn't have a strut brace): Then couldn't help myself but to fit the airbox, battery and a mock intercooler charge pipe. Needs a good scrub, but really like how it looks neat and OEM, like it belongs there. Still need to put the battery box cover on, which should tidy that area: Getting closer now. Still got the wiring etc to finish altering inside, but getting the engine in and the front back on felt like a big hurdle was jumped, and made the project feel like it moved forwards a lot.

A lot of you may not know, but myself and my fiancee were expecting a baby yesterday. Unfortunately we lost him at 24 weeks to a horrible genetic disorder called Wolf-Hirschhorn Syndrome. My fiancee and I (and 7 other friends) are all running a 10km cross country run called the "Sole Destroyer Muddy Run" on 19th March. Neither me nor Lauren are runners, so its been a bit of a shock training, its not something we have just been able to do willy nilly! We are trying to raise as much money as we possibly can for a charity called SANDS (Stillborn And Neonatal Death Society), who we owe our sanity to for helping us through the hardest time of our lives. If you don't know what SANDS do (hopefully none of you ever have to use them), its well worth looking them up. Please could you find it in your hearts to donate as much or as little as you can afford at the following link, and clicking on one of the names (preferably mine, so I can catch up Lauren!). Once you click my name, there is a story there if you want to know more: https://www.justgiving.com/teams/Oscar We are at £1,485 at the minute, and I have a friend who works for Barclays who is going to double whatever we make...so I am trying everything I can to get our donations up to £2000, so we raise £4000 in total! So please, if you can spare a little pocket money, I would greatly appreciate it!

Managed a little bit of TT work between private jobs this weekend. After test fitting the engine, I found the stock TT heatshielding was going to interfere with the turbo coldside and intake pipe. The turbo position on the 1.8t points the turbo hotside to the driver side, hence all the heatshielding. The tdi turbo points the opposite way, with the hotside to the passenger side, so the heatshielding isn't needed. This is the before picture: And this is the after. The eagl-eyed amonst you will also notice the power steering line on the driver side has also been fitted, the brake servo vacuum pipe fitted, and the A/C lines swapped (see below): The petrol and tdi A/c lines are very slightly different at the ends. This meant the original TT lines don't fit the tdi engine because the angle of the end stops it bolting up. This meant the entire A/C line setup needed to be swapped over. Tdi A/C pipe connection to engine: TT A/C pipe connection to engine: As you can see, not much of a difference, but it was enough to stop it bolting up. Whipped the old dead turbo off, and gave the gasket faces a clean up: Also gave the new inlet manifold a bit of a scrub up: Unfortunately that's all I had time to do. I had bought a turbo on ebay, but the guy decided that he wasn't actually going to send it, and is now ignoring any communication. All covered by Paypal, so will get my money back, but annoying none-the-less!

A little update, not much to show really though. I'm at the mocking up stage for the turbo/inlet/turbo intake. The standard PD130 setup looks like this, with the turbo intake pipe pointing to the right, and the inlet manifold pointing to the left. This then runs down the engine and into the side mounted intercooler in the drivers side of the front bumper, then back into the turbo cold side outlet via the wheel arch (ignore the arrow, its just a random picture stolen off google): Looks ok-ish as stock, but the pipework is a bit restrictive, and the side mount intercooler is rubbish. When the majority of people fit front mount intercoolers to the diesel engines, you end up with a mass of pipework in the engine bay, which looks awful: The plan is to use a Passat PD130 inlet manifold, which faces to the right rather than the left, which should create a much better pipework route, which should look something like this: So, I ordered the inlet manifold, and the alloy turbo intake pipe (the original one for the PD115 engine which the Golf originally came with). Then set about remove the old setup, and fitting the new. Bolted the inlet manifold on, all matches up a treat. Went to bolt the turbo intake pipe on...bugger...it fouls the intake. The PCV take off hits the inlet, and the way the end of the pipe curls round means it will hit the pipe that attaches to the inlet manifold : My plan was to chop the pipe up at the welded join, and adjust it there, like so: So I set about doing that. It turns out with a silicone joiner, the pipe can be twisted and extended by about 2 inches to be in the correct position (shown here with the pipe off the inlet manifold temporarily cable tied in position). Just need to extend the pipework for the PCV valve between the rocker cover in turbo intake pipe: Also bolted up the gearbox to check the clearance between the turbo and the transfer box, its reeeeeally close:

Todays progress...slightly more successful day! De-pinning parts of the Golf loom for the bits I need to swap over. The OEM loom tape is SOOOOO sticky, horrible stuff!!! Diesel throttle pedal loom split from the loom. 6 wires direct between the pedal and the engine (via the blue plug in the scuttle panel), and 1 goes to relay 109 which supplies ignition power (the taped up one) The aforementioned relay 109. Red wire goes to terminal 30 (permanent power), blue wire goes to the fusebox. All labelled up and ready to be integrated into the TT loom It fits! Only a test for at the minute though, I wanted to see how it sat in the bay, and to get an idea of the downpipe route (which I don't think will be too bad in all honesty, will be similar to the TFSI turbo downpipes). Just need to take one of the heatshields off the bulkhead because the turbo intake pipe catches it. Will pull it back out to change the turbo and inlet (going to use a Passat PD130 inlet, which has a right hand entry rather than the standard left hand...which should mean a far better FMIC route (similar to the K04 charge pipe, but the opposite way around)

I shouldn't think a box with a crown wheel not attached will be going very far, so you should be ok

If you supply the LSD I'd be happy to build it into the box for you.

Nothing but set backs this weekend, stuff I thought would be simple turned out to be a ballache! Started off with the clocks, the plan was to pull the front fascia off the TT clocks and fit it on the Golf clocks (the dash binnacle is a different size/shape: Once I got the clocks from the TT out, I realised they are 3 plug versions, not 2...first problem! All the pinout work I have doesn't mention this third plug on the TT loom, so need to find out what that contains, there's not a lot in it, so hopefully it's something additional (like radio controls etc) rather than something intricate to the loom: Split both the clocks apart, and got ready to swap the fascias...bugger, they aren't interchangeable! The PCB on the Golf clocks is 2mm bigger all round, so it won't fit inside the casing: Managed to get around it by drilling the hole for the 2 buttons on the front of the binnacle (for clock setting and trip reset) slightly bigger so the dials then sit flush against the PCB. I'll need to use a couple of cable ties on the back of the PCB to hold it onto the binnacle, but they are almost perfectly aligned with cutouts on the PCB, so not too concerned about that...and it's all hidden anyway: Next up was swapping the gearbox guts over. The TT is 4WD, but has petrol ratios. The Golf has the correct diesel ratios, but is only FWD. They are both the same 02M box, and people often swap the petrol ratios out on petrol boxes for diesel gears when bigger turbos are used (when longer gears are needed due to boost coming in later). My plan was to put the diesel FWD gears inside the 4WD box. Started off by draining out the oil from the FWD box (engine crane coming in handy again!): Whipped all the bolts etc out, and split the casing off: Then did the same with the 4WD box (one side of the casing is exactly the same, the bell housing side has additional mounting holes for the transfer box, and has oil passage ways to supply the transfer box with oil). The transfer box isn't particularly big, but it makes the box assemble a shed load heavier! Stripped the transfer box off, undid the bolts etc, and split the box open, then laid the 4WD and FWD boxes together: At this point, the only visual difference was the extra length of one of the output shafts on the 4WD diff (to accept the shaft from the transfer box): However, this is where it all went wrong! It turns out the diesel crown wheel gear is ever so slightly bigger than the petrol one. Once the 4WD box with the diesel gears was back together, it wouldn't turn in any gears, only in neutral. Thinking perhaps I had made a cockup with the reassembly, I tried the other box, and I couldn't even get the diff in because it's bigger, so the gears wouldn't allow the shafts to sit inline. Bugger. The only way round it is to drill the rivets out of both diffs, and swap the crown wheels over. Bit of a ballache to do, because the rivets are mega hard, but I did it before on my LCR for the LSD, so know it can be done. It does also mean £100 ARP crown wheel bolts need to be bought, which adds more cost to the project, but needs must! Today's task is to measure the diff rivets PCD to check the spacings are the same, before I get too deep into drilling the rivets out! I ended up putting the boxes back together as they were...wasting about 6 hours of the day, slightly annoying! Just the joys of a bespoke project like this I gues!

Haha, thanks! I'll reserve my gloating until it's actually running though

There is an engine loom and a body loom. The engine loom plugs into several plugs in the scuttle panel. The plugs are the same in the diesel and petrol, but the pins do different things, so I just need to figure out which pin goes where. That way the TT body loom will remain untouched, apart from the pins being in different places in each plug. The dash plugs are also slightly different between petrol/diesel (and the physical dial differences with the Rev gauge etc), again though, they can just be re-pinned. I was originally intending to just literally swap the whole loom from golf to TT, but the 4wd "brains" is largely in the ABS pump and Haldex unit, neither of which the golf had, so swapping entire looms would be a backwards step (plus the golf was a 5 door, not a 3 door. Fuel system wise, it should just be a case of fitting the diesel lines from the engine bay to the petrol tank, and swapping the 4 bar petrol pump to a 0.6 bar diesel pump, the actual tank itself is fine (as long as the petrol is drained out of course!)

Just going to use the newer PD115 ecu, apparently that can be mapped perfectly fine. Got the whole Golf loom pinned out, now working on the TT loom, then I can compare the two.

Crimping/soldering obviously isn't your forte

Already wangled some coilovers out of him, haha.

They are, but they are on wiring diagrams, so you have to transpose them onto a list like I have done. Bit of a ballache, but saves looking through pages of diagrams when you're sat trying to put pins in plugs!

TTtdi Update: Just finished the pinout of the Golf's ecu and connectors (200+ pins!): However, the car is a PD115 engine, the guy I'm building the car for wants to temporarily put a PD130 turbo on to get it up and running until he saves for a big turbo. The PD115 ecu's aren't very mappable, so he wants to fit a PD130 ecu. Annoyingly, having compared the pinouts between the 2 ecu's, the PD130 has a few extra sensors, and several wires are in different places (the PD130 ecu is a lot more intelligent, and has a lot more map areas, so is more tuneable). The PD115 engine obviously doesn't have these additional sensors, and the PD130 ecu will be looking for them, so a PD130 engine needs to be fitted to get them talking to each other properly. That pretty much means I have wasted the last 3 nights doing a pin out on the PD115 ecu I am trying to convince him to just stick with the PD115 engine and ecu with the PD130 turbo for the short term (the PD115 ecu can be mapped for the PD130 turbo, but not really any higher). Its either that, or he needs to get a complete PD130 engine and loom, which is about £300 ish. Slightly annoying really, we both assumed they were the same engine, just with different turbos and injectors. It's not until you look into it further that these

Bit of bedtime reading for the TTtdi. Each booklet has 15+ pages of wiring diagrams. Going to be dreaming pinouts!

Luke, do the main caps too. You'd be a fool not too at this stage. Get the block honed, then get it hot tanked. Start the upgrade with a totally clean base. From experience I wouldn't ever re-fit standard size pistons into an old engine again. I did that, and although the piston rings were on the "loose end of acceptable", I ended up with piston slap, which sounded shite when cold. I'd go for 82mm or 83mm, that way you ensure you have a fresh bore that is perfectly round and within tolerances.

Engine out of the TT today. A lot more involved than the Golf, the bay is really crammed, and with the 4wd box, access to the turbo and downpipe bolts is a real pain...but got there in the end! Got a nice pile of K04 bits to post out for a 1.8t A3 conversion, should recoup some costs (actually pays for both cars, they were that cheap!): As usual, I forgot to take pictures of the important stages, haha.

No, he has a gay little red lipstick faggot machine now I should be able to do any of those dates to be fair. Either in the S3 or the TTTdi (if its done by then)

Cool tape.