Mk2 vr daily

[Shiver 11]

Ok it begins a half attempt to build this by two guys who didn't really know what much and no doubt was sold on cheap as it didn't work and I took it on.

[Shiver 11]

New loom and engine harness

Got cracking on the loom tonight. Old one ripped out and new tidy one fed in ready to tidy it all up and make sense of it.

Fuse box was a right state so it was all unplugged and untangled as it was just too tight and unable to work with.

Alot tidier

Started on the engine harness but didn't get round to finishing it as I need to turn the lump around so maybe on Sunday

Heated washer jets cut out, crappy stereo loom taken out ready to make up a new one when ready, started taking the centre console out but left the grips at home so couldn't get the matrix out which needs to go to get the carpets out the front.

[michael5556 247]

Wicked

[Shiver 11]

The new shell turned up today and sods law it a raining all day while were outside working on the cars.

Today was swap the mk3 beam and subframe from the red shell to the new grey one, then mk2 onto the red one so it could be towed away later.

It all went well thanks to having four of us to life and move everything, the only down side was working in the rain laying on the floor getting soaked atleast it's done and the build and move forward now.

As it turned up

Rear beam done

Subframes coming off

Going back on

Sad to see her go

It begins

[Shiver 11]

Got started on the new shell today been waiting all week to start it. Wanted to get it dry as the passenger foot well was full of water, turns out it's all coming from the heating matrix so that'll need replacing.

With all the bits coming out I could get a better look and found out at some point it's had a crash and a repaired with a new door and looks like a full respray which can be flatter to look new again so not so bad.

Rolled the car out and worked in the sunshine which was such a nice change to get the doors off

Soaked carpet after a year of sitting

Dash out

The doors came off easier on the 5 five which was a surprise

Engine bay before I took out the servo, clutch cable and other little bits that are just on the way at the moment

Before and after of the engine bay being cleaned, there is alot of built up grease and wax in there so I done some much until I get a heat gun to save the paint.

[Shiver 11]

Having got out of work early it was off to the garage for more fun. Took an angle grinder to the old manifold as the centre section was stuck we bolted the subframe up with it in place and even if I did free it up it wouldn't come out.

The cutting wheel was too small so I had to cut it at different angles and took an age but got there in the end, shame the centre is still stuck so that's as far as that Job goes for now.

Out came the sound deadening as it was soaked and mouldy thanks to a knackered heater matrix going pop.

Engine and lighting loom in got some way through plugging it in but my brain isn't up for finishing that tonight.

Pedal box in but I need to mark up the bulk head to drill and cut new holes for the hydraulic clutch.

[Shiver 11]

Got my hands on all the bits to get my brake lines made but got in the post another 50ft copper line just in case

Cut and drilled the holes for the clutch shame it went abit side ways at the start but nothing abit of sealant won't fix when all fitted.

Armed with my heat gun I got to work on removing the wax and grease as the engine bay was totally caked in it. Once it all started coming off I noticed more and more rust spots so took out the wire wheel and I wish I didn't start! The sealant takes forever to come off and there's loads of it but it'll be worth it in the end.

[Shiver 11]

Got some new wire wheels on order including a knot one to go on the angle grinder

Mk3 universal joint fit

Had to cut the bulk head to bolt up the pedal box as the top mount is 15mm over

It's so nice to have steering again instead of kicking the wheels to roll her out

Started working on the rust on the floor panels and sorting the flaking tar with a heat gun ready for when I fit the new sound deadening.

Had enough of not finding anything so it all came out and a good cleaning while th sun was out

[Shiver 11]

Decided to stop fussing about and got on with fitting the engine harness and dropped the engine in which isn't that fun on your own without the crane.

[Shiver 11]

Well the plan for getting the engine started this weekend went out of the window thanks to not having a 109 relay so got on with cutting the exhaust out, engine out and drive shafts out of the way then back in, gear selector bolted up.

Need to repair the loom I wrecked with the wirewheel on the angle grinder whoops. Main positive and ground need to come out of the lighting loom then charge the battery and fresh fuel hopefully!

[Shiver 11]

Managed to repair the loom I clipped with the wire wheel luckily it was only one wire that got cut in half the rest were light grazes so nothing major.

I stripped the lighting loom back to take out the main positive and found so previous damage from the last owner hidden by some tape

For afew months ive been fighting with this ground anchor from last owner and today had enough of it getting in my way so attacked it with the grinder haha!!!!

Bolted up the cross member and noticed my engine mount doesn't line up it's too far back not sure what's up with that

[VR6Pete 1,455]

A lot of awesome work going on here! Looking forward to seeing it done

Club Chairman

[Shiver 11]

The day started with the plan of getting the old back box cut off and hang the system that came with the red shell. First thing noticed was the centre section was a good 12inches too long so cut it down and now the pipe is the same width as the de cat so will need a sleeve to hold this up properly.

Once the engine was running we noticed It was stuck in gear but the previous owner had unbolted the selector on the gear box so decided to take the engine out ,gear box off and try the spare I bought the other month.

It's always a big gamble buying secondhand from eBay so back in and running.......Ching Ching Ching Christ it's knackered!!

We were abit confused as what this is inside the bell housing

Turns out I had not put the spring on the bottom of it so it was flapping about so be warned always clip it on and held in place.

After having a long day on the car we really coildnt be bothered with it but carried on gear box back on, engine back in and running. The noise has gone and the hesitation on power has stopped so it must of been the maf and lambda causing that. Shes sounding like a Vr even with the huge blow from the centre.

Video below

http://i97.photobucket.com/albums/l204/shiver85/de1e7eeb.mp4

[Shiver 11]

Well the time has come me and madmanluke dusted off the tools and cracked on with this build. It was left on hold until lukes new engine was confirmed and near being collected.

All of his running gear was put on my shell today ready for the real work to begin. I wanted to change it all again that way it's all from one car which we took apart when he vr conversion was first done two years ago.

Once the old beam subframe and engine are out of my garage we can carry on pushing this one forward.

Well the engine now runs smooth again in this car after it came out running lumpy in Luke's. Not sure why it's stops popping and banging but it's early days. The exhaust is a good 6" too long so will be chopped up and welded this week then hopefully it'll hang nice.

Been spending again since my last update:

A set of weller steels to be banded were thinking 7.5" to keep the gti arches

eBay special coil overs

Willwood bias valve

Slim rad fans

Top shock mounts all round

Rear discs

Exhaust coupler

Cv boot (managed to rip the new one)

Brake lines and unions

Spark plugs and filters

Oh yeah here's why my car has been on hold I bought a new toy

[Shiver 11]

Managed to find a new home for the car as I was getting too much grief from the locals. Found an outside space as the garage already has a car sitting dormant in it but a cover and gazebo will do the job in our British summer.

Spent yesterday putting the doors, bonnet and front end on then packed the car up with everything in the garage.

On its way

Whoops

[VR6Pete 1,455]

Good update. Lucky the wire wheel didn't cause more damage lol

What was the score with the engine mount not aligning up properly and how cone the locals were giving you troubles???

[Shiver 11]

The engine mount was off as I had tightened the rears down and the front cross member was slightly off. So engine raised and everything loosend it all jigged in line. Bolts loosely in and then engine down and bolt up tight.

It was only one jobs worth who caused all the issues for me looked like the child catcher. He moaned about the slightest oil spill and every hammer blow. Was so glad to be shot of that garage but the new location wasn't ideal.

The grey shell went up for sale as the black shell we built before was being sold and it made sense to buy it as the engine bay had already been shaved and all round better condition. Ended up scrapping the grey one and starting all over again for the third time

[Shiver 11]

Sad times another one gets scrapped

Lots of conversion bits for sale though

Tyres have gone flat so new valves needed or wheels

Attack the flaked paint in the bay and repair

Wash and run the looms

Well hopefully

Now with the car in her new home I realised with winter round the corner and it being dark by the time

I get home I was gonna be knackered working on the car as the garage has no lower nor are there any street lights. I was using my rechargeable strip light with the car battery and inverter but it wasn't really ideal.

I trailed eBay looking for a way forward and stumbled across some mr16 type bulbs with LEDs running 12v. They claimed to be 4w and were cheap enough so I trailed one with some connections and here's how it looks with just one.

I've now got 5 more in the post and picked up a 10w led flood light that'll run with the inverter so hopefully ill have a nicely lit garage but it means I was have to walk the battery's home every time they die to charge them

[Shiver 11]

Yeah i used the battery that came with the car then clamped the 300w inverter on (from maplins) then wired on a 240v 5amp plug and on it went does the job lovely with the second used as a lead lead light or mounted at the back.

Speaking of my power issues running an inverter I've been looking out for another battery and by luck i spotted this by my garage

it's been on my optimate since Friday cycling it afew times hopefull it'll come good to run the likes.

Second light in and decided to make use of doors and hung some tools

The engine loom went it

Never ever ever ever ever ever again!!!!!!! Am I changing the high pressure power steering hose with the engine in. What a nightmare I tried to take the 6 branch off as I couldn't get the 18mm spanner onto the union. Turns out I've got a rounded nut and a spinning stud on my manifold so gave up with that and just took the decat off and a fraction at a time undone the hose.

3.5 hours later......... It's all Bolted up fluid in and I left for the night

Well the wellers got sold on as I couldn't band them to what I wanted and 3 of the vr wheels I had leaked on new tyre so the plan was get to over to have the tyres taken off and powder coated all within a week maybe two at a push........................

5 weeks later of being messed around the wheels got refurbed and powder coated then new tyres back ok and balanced I'm happy with these until I've got the funds to get something else. Should have these on tonight and carry on pushing this build forward.

[Shiver 11]

Tonight we braved the -2 and freezing fog to get the fluids in it get the car outside and run it up to temp for the first time in over a year since owning this engine. All went well until after the fan kicked in then turned off the engine cut a minute later and now the fuel pump relay is clicking like mad.

Lots of things now added to the list and hopefully will be back on it tomorrow with a fresh mind.

Well tonight I managed to break this

And this

Changed this

Done this to stop the positive arcing out on the slam again

I reckon a could get away with this

[Shiver 11]

Tonight was

Fit the head unit and speaks (only fronts)

Fit drivers seat with new rail guides

Bleed brakes

Fix headlights (dead fuse box)

Fix horn and fit steering wheel

Tried to bleed the pas pump (need a new one)

Wire and mounted vdo gauges

Fixed tail lights

Took it for a quick spin

The car didn't cut once on us so seems the warm start issue was slightly loose grounds for the ecu

Well the day started with a flying trip out to Essex to pick up a pas pump as mine had died but got to the m25 and it was closed thanks to a nasty crash on the a13 junction. Finally got through picked it up and then spent 4 hours of life in a speed awareness course for my sins on the bike (better than 3 points) straight home and swapped the power steering pumps over bled up the rack as best as possible.

Slapped the grill on and plugged in the lights I've got a dead side light but the rest is fine so on went the bumper and off I went for a quick spin (around the private land of course) it just needs tax and mot then it'll be on the road. I still need to go back over pretty much the whole car just to double check everything but its almost there

The day of reckoning is here. The drive towards the workshop was fun the dash buzzer going nuts because my vdo oil sender wasnt on, a nice rumble from the front and just when I got near by it cut out on me! Left for 10 mins fired back up and it was full steam ahead with fixing the side light, pulling the fog lights out (one is busted), aligning the headlights, welding the back box bracket up and bolting up the wheels.

It's at the mot station now just gotta wait and see....

[Shiver 11]

Fast forward over a year since the mot

Engine out to clean off the over spray

http://i97.photobucket.com/albums/l204/shiver85/9D419BAC-3DA5-402D-B694-ADC39A17AC33-1689-000000C59AF47DA2_zps5881ca0b.jpg

http://i97.photobucket.com/albums/l204/shiver85/1241889C-BD10-4945-94C9-B05107F4A3A8-1729-000000EEFDD7F3B6_zpsdb1df07f.jpg

http://i97.photobucket.com/albums/l204/shiver85/D367B509-3DC0-4C3F-A2BB-3DD4210B4655-311-00000014FCD35A9A_zpse62a1305.jpg

http://i97.photobucket.com/albums/l204/shiver85/298968DB-F585-494B-A650-244B80095C36-2898-0000015CECB44199_zpsb061d814.jpg

http://i97.photobucket.com/albums/l204/shiver85/941EEF41-332C-4443-85BB-7705590A0583-5283-000002B381E16D77_zpsd623a627.jpg

[Lukey. 381]

So your oil cooler burst and caused the cream?

Nice mk2 VR

[Ickyketseddie 89]

Mega car mate.

Sent from my iPad using Tapatalk

[Shiver 11]

Dunno what happened to those last pictures hopefully this works.

Yeah the oil cooler packed up was panic stations thinking the head was gone but luckily wasn't.

The car is having a massive overhaul as it was a matter of time until I was happy enough with how it was all going.

The new parts list is a joke but you get an idea with the pictures and updates to follow over the next few weeks