So it begins...

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Spud
GTI Driver
Posts: 93
Joined: Wed Apr 30, 2014 9:29 am

Re: So it begins...

Postby Spud » Tue Jan 08, 2019 8:25 am

Wow didnt see that coming. Well done

PDF_27
Stage 1
Posts: 399
Joined: Wed Sep 05, 2012 8:36 am
Location: Centurion, Gauteng

Re: So it begins...

Postby PDF_27 » Tue Jan 08, 2019 9:49 am

Absolutely mad! Would love to hear this baby at WOT!

shygolf
Stage 2
Posts: 586
Joined: Fri Aug 19, 2011 1:33 pm

Re: So it begins...

Postby shygolf » Tue Jan 08, 2019 10:25 am

Wow what an upgrade!
Ex 2012 Mk6 GTI CW DSG REVO2+

Ex 2008 White Golf 5 Gti DSG REVO3 K04

Regards
Hoosen
072 135 7861

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Slowboat
Stage 2
Posts: 789
Joined: Wed Apr 30, 2008 9:29 am

Re: So it begins...

Postby Slowboat » Tue Jan 08, 2019 8:21 pm

Thanks guys and yes she does sound wonderful at WOT. Same R32 Wookie roar but a bit deeper sound to it.

More details to come through with plenty of pictures.

But for now I need to confess that I was actually busy on another project before this project.
That project made this R36 project happen.

Click on The CC Story for more details and more pictures ;).
If you're behind, you're slow. If you're in front, you're in my way.

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MKV GTI build specs: My MKV GTI Big Turbo build specs

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Slowboat
Stage 2
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Joined: Wed Apr 30, 2008 9:29 am

Re: So it begins...

Postby Slowboat » Sun Jan 27, 2019 4:10 pm

Here's some video clips.

Going up a steep hill:
Youtube Uphill run

Idle/rev in the garage:
Youtube Idle/rev in garage

The engine check light is on due to no catalytic converters. The ECU software needs to be updated.
If you're behind, you're slow. If you're in front, you're in my way.

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MKV GTI build specs: My MKV GTI Big Turbo build specs

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Slowboat
Stage 2
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Joined: Wed Apr 30, 2008 9:29 am

Re: So it begins...

Postby Slowboat » Sat Feb 23, 2019 7:29 am

Getting ready to remove the 3.2L engine.
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Before disconnecting the aircon radiator and it's piping I did a quick cleanup.
The was a small seepage of oil from one of the valves. The valve needs to be replaced.
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After a quick cleanup.
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The ME7 ECU that needs to be taken out, with it's engine wiring harness.
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The back view of the VR6 3.2 motor and gearbox, once out of the engine bay.
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Engine bay needed some cleaning.
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The engine bay all nice and clean.
Ready to receive the 3.6L engine.
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The 3.2L at the front and the 3.6L engine at the background.
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The 3.6L installed.
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I was toying with the idea of using the R32 gearbox since it is a close ratio gearbox.
After a while, I made a decision to use the 3.6L gearbox.
The first three gears (1st, 2nd and 3rd gears) ratio, of 3.6L gearbox, is almost identical to the R32 gearbox ratios.
From fourth and upwards of the 3.6L has longer gear ratios that the R32 gearbox.
With highway speeds, in sixth gear, the R32 sits way above the 3000rpm.
At the same highway speeds the 3.6L sixth gear sits around the 2500rpm mark, which is a big difference.

More later on.
If you're behind, you're slow. If you're in front, you're in my way.

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MKV GTI build specs: My MKV GTI Big Turbo build specs

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Slowboat
Stage 2
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Re: So it begins...

Postby Slowboat » Sat Mar 09, 2019 10:16 am

Once the 3.6L motor was installed, it gives me an opportunity to strip off the inlet manifolds to view the carbon build up on the inlet valves.
This VR6 has done 150 000Km and it is the direct injection (FSI) motor.

Stripped the top part of the inlet manifold off.
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Here's the three front part of the inlet ports:
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The three back part of the inlet ports:
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They are not too bad for the mileage, but they needed to be cleaned.

So walnut shells are needed to do the cleaning. It wasn't easy to find.
Someone told me that they got the nut shells from a gun shop.

So I went and bought some nut shells from a gun shop.
Also needed other equipment, 50L compressor, gravity feed sandblaster, carburetor cleaner, vacuum cleaner with some old vacuum cleaner hoses, etc..:
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I was lucky to have a few 7mm aluminum tubes laying around.
Bought some extra nozzles, drilled the holes bigger and fitted the aluminum tubes onto the nozzles.
The top curvy one was used to get into the back ports in the head. I really struggled in cleaning those ports.
The bottom straight one was used for the front ports and that was easy to clean.
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I also used this cheap USB bore camera to help me to view the back ports while cleaning.
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Taped up the ports and left the port open that I was cleaning.
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This is about 15-20 second squirt from the sand blasting gun with the nut shells.
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After a couple of minutes of blasting and a round with the carburetor cleaner.
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Just one more round with the carburetor cleaner and the port cleaning is done.

The back ports cleaned out and waiting for a last round with the carburetor cleaner.
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I really struggled to get the back ports cleaned out properly.
It was difficult to get in there with the aluminum tube, but with some persistence I eventually got it cleaned out properly.

I use an old vacuum cleaner hose, which I cut into a short length and made a small hole for the aluminum tube to fit through.
The old vacuum cleaner hose was just big enough to fit into the inlet ports.
This old hose was connected to my old vacuum cleaner and the area was kept clean from the nut shells spraying around.
One advise on the vacuum cleaner, either use a low power one or if yours is a variable power type, like mine, set it towards the lowest setting.
At higher suction power I actually started to draw out the oil from the valve stem seals.

Used a strainer to separate the bigger carbon pieces from the nut shells so I can reuse the nut shells.
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This is how much nut shells I've used.
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I lost count after 15-16 times of reusing the nut shells.
So the 3Kg nut shells would do a few cars (4 cylinder).

Installing the seal kit onto the injector.
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The top half of the inlet manifold cleaned out with new seals, ready to be installed.
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Once the inlet manifold was installed another area I had to tackle was an oil seepage from the sump seal.
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The sump dropped.
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The internals looks very clean for the mileage done.
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The sump all cleaned up and ready for the install.
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Next up is the exhaust install and the wiring.
If you're behind, you're slow. If you're in front, you're in my way.

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MKV GTI build specs: My MKV GTI Big Turbo build specs

turbodub
Stage 2
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Re: So it begins...

Postby turbodub » Mon Mar 11, 2019 12:12 pm

brilliant!
if somehow some shells should escape into the combustion chamber i am told that they will burn up before they do damage- do you think this is correct?

Moolz
Stage 1
Posts: 463
Joined: Tue Apr 24, 2012 9:08 am

Re: So it begins...

Postby Moolz » Mon Mar 11, 2019 3:05 pm

Another awesome build! Wow.
01' Mk1 - 1.6i (76kw / 140nm - RBTS)
12' Mk6 - GTI

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Slowboat
Stage 2
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Joined: Wed Apr 30, 2008 9:29 am

Re: So it begins...

Postby Slowboat » Thu Mar 14, 2019 12:15 pm

turbodub wrote:brilliant!
if somehow some shells should escape into the combustion chamber i am told that they will burn up before they do damage- do you think this is correct?


There shouldn't be any shell pieces escaping into the cylinders in the first place.
The inlet valves must be in a closed position (compression/powerstroke for that cylinder) and the other ports tapped off.
If there's a couple that somehow went into the cylinder it should be okay as it will be blown out of the exhaust port or burnt off.
If you're behind, you're slow. If you're in front, you're in my way.

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MKV GTI build specs: My MKV GTI Big Turbo build specs


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