Golf Rallye 2.0 TFSI + Haldex 2gen

[2fast4you]

Ok here is how everything went :

I own a Golf Rallye and I'm  starting a engine swap. I have my eyes on an 2.5 tfsi engine from an  Audi TT RS witch I haven't found yet but I will.


















This are the parts that I already bought. Because my Rallye had a bit of rust on the front wing I had to find a new one








and I bought spare front and back fender


Haldex gen.2



ABS and the pump from a Golf 5 R32



Another spare pair of headlights



Dashboard from an Audi A3(leftover from the previous project)



Prop shafts:



one from Audi TT and another from a Golf 5 R32

And some more parts have just arrived

Recaro Speed seat



tail lights:



and the steering wheel




Going on with the dis assembly



I am removing the paint because I'm looking for rust and I was thinking to be repainting the body in tornado red or maybe...

[2fast4you]

I bought these wheels





But I figured that those wheels are too big so I bought the OZ ultralegera 17x8 5x100







I thought these are the wheels for my project

What do you think?



I  have stopped removing the paint because when I'm done with everything I  will take the body shell to sanding and let the professionals do their  job.This is what I am doing right now.

And started fitting the MK5 dash





and modifying the rear axle to except the Haldex 2nd generation

first taking measures



then cutting and starting the fitting







the first holder















and bought a pair of front and rear Brembo brakes from a Touareg



here is to see how much space is the gen.2 haldex is going to take





and the work that has been done around the fitting of the dash

first of all I bought a new subframe



and the original Golf 5 holders that the sub frame is tighten to and cut them to fit





then more cutting



and then started making some pieces to weld on the chassis that would except the holders for the sub frame







after I welded the holders I cut the rest of the sub frame to fit between the pieces







took the sub frame to be welded and here are the results:





and...







after the sub frame was fitted next was the intake for the air conditioning



first I took a part of the air conditioning to be a little modified





and then everything could be welded



After all of these I had to redo the shifter because it had to move 2 sm back ( it was too close to the dash)










Then bought these Brembo 4 pot calipers because I've mounted the other ones that I had on the Audi S2 project that I've been working on so the Rallye gets them brand NEW.

[2fast4you]

finished painting the Brembo's and this is how they look now.








opened the hole for the MK5 Heating



and done the engine mount








and  something very important to me is that finaly I finished my garage.  When I started mu project I got some comments saying "that's a creepy  garage"
Well lets see how you like it now










Then some parts (of the many that I ordered) arrived so here they are:

The front disc 323x28 punched from Seat leon Cupra



and here they are with the BREMBO's



OMP Competition Belt 3", 4 fastening points x2



and more to come

the powerflex for the front axle



I  also ordered adapters for the brembo and been waiting for them for a  month. They newer came, so I email ed the firm that I bought the  adapters from and they told me that they haven't sent them yet   because they are inserting some new features on them
In the mean time I will be painting the complete front Axle with the control arms


And some more parts






The front axle was sandblasted covered with primer, painted and finally assembled













bought a steering rack from VW Polo 9N and the servo motor

[2fast4you]

and the Brembo Adapters came finally after 2 months of waiting



and after I had all the parts in one place everything started to come together as it should











and I must say that I've had help from Mario. You must ask you're self "who the f..k is Mario"
Well  Mario is the guy who's car was the inspiration for me to begin with  this project, you can find his project a MK2 golf with a 2 liter TFSI  engine and doing a very good job here is a link of his site where you can find some info and pictures of Mario's Golf.

http://www.golf2tfsi.de/html/home.html

I think he is watching this thread so I will use this chance to thank him for his help "THANK YOU MARIO"
Although I'm not finished with you I will need some advices in the future


I'm  getting ready to finish up some minor things around the dash and start  building a Roll cage. In the mean time the only part that was ordered,  and arrived were the H&R triple C chamber bolts




I'm just about to finish up the rear axle
This is how the rear axle looks:











one of the things I need to finish are these for Camber/toe adjustments



I bought these from my local VW dealer they are from Audi RS6 rear axle, you can find them on the ETKA as part number:WHT001682   that is if anybody needs them. All i need to do now is to make  camber/toe plates. If you want these all done you can find them on this  site:
http://www.dutchbuild.com/index.php?page=shop.product_details&flypage=flypage.tpl&product_id=87&category_id=15&option=com_virtuemart&Itemid=104&lang=en&vmcchk=1&Itemid=104


gathered all the screws and nuts including the ones needed for the chamber adjustment and took them to be chromed.



and how they turned out









not perfect but OK

OK finally came the last parts that I needed to finish the rear axle.

Powerflex





And  these are the rings and the bonded aluminum bush that I need to finish  the mounting points on the axle. There are going to be 4 mounting points  something similar to the factory rear axle from golf Mk5 4 motion



and  the piece between the rings is an adapter that I need to combine the  Golf Mk5 brake master cylinder and the 94 Passat VR6 brake and clutch  pedals. And when these piece is welded it should look like this:
















I also took the rear axle holder to be chromed



the Roll Cage from OMP arrived :

[2fast4you]

... so the work continues

I finally found a Lancia delta Integrale hood
Here are some pictures







I was looking foe these hood for a ling time and finally found one :peace:


finished installing the roll cage . The roll cage needed some modifications to accept the Golf 5 dash but finally it's done Here are some pictures:















And here is the support to the suspension housing from the roll cage that I planed on doing
What do you think?























finished the rear reinforcement







also finished the front reinforcement from the suspension housing to the roll cage









so moving forward with the project


Today I finished modifying the tunnel to receive the Golf MK5 selector mechanism .
Started by cutting a bigger hole for the selector mechanism and drilling holes to get it fixed:



the small holes were made to remove the MK2 selector mechanism mounts



did some modifications on the tunnel to fit the MK5 selector mechanism



and here is how it came out:








in the mean time I mange to find time to build this :









so I can move the shell in mu garage
and some shopping was done:
Rear 4 piston calipers from Shevrolet Camaro SS 2010+ for the rear axle



brake disc for the rear :



also bought H&R FRONT SWAY BAR VW GOLF 3 VR6 25MM
and the emblems:


Finally finished the roll cage

[2fast4you]

also sorted out the pedals







and the most important thing for me, the gearbox mount











still some minor things to be done and then... off to the paint shop

Then I remembered that I have something that could help me... a 4 motion DSG gearbox









from the looks of it everything should be OK but will see.

the interior has been cleaned of the isolation and primed





the gas pedal has been installed





the ABS pump was also installed





installed the handbrake





and the upper reinforcement fixing screws







finished the fuse box:





there are only 2 things to finish now and off to sandblasting and then directly to painting
Sand blasting done and off to the Paint shop













I took the bumpers to be fixed. I closed the holes for the fog lights and filed in some bumps and cracks










Finally something done on the car

Closed the gas tank cap



The place for the battery















and the rear lower reinforcement





something more coming up !!!

[2fast4you]

Today arrived some new parts that I ordered:

Porsche 944 door handles







and the front Rallye grill without a VW logo from Mattig



The roll cage and the rear axle were put in filler and after that the rear axle was painted:













Installed the Haldex





and one of the drive shafts







That is all for now

Because my car is at the paint shop I havent done no progress. But I have upgraded mu garage "TUNING GARAGE" as I like to call it ;)
A new ELECTROMECHANICAL 2-POST AUTOLIFT from WURTH (OMCN)



Finally the car has been put in first hand filer... and looks nice :p











The hood is almost finished. It took a lot of thinking and work but it's almost done :D













and the parts that I bought 3 months ago from U.S finally arrived

the rear calipers





and the H&R sway bar





And finally the hood is finished :)













everything fits as stock. All the lines are aligned :D

Audi R8 Calipers






now to figure out how to make the brackets  :banghead:



Also the front end of the Rallye got together and now its time to correct every line that needs correcting and realigning ;)





The car was sanded and put in second hand filler









the bumpers:



closed one of the holes for the front wind screen wipers and the rear one also

[2fast4you]

Did some shopping:

a set of Bi-xenon headlights from golf 5 to use the lenses with the shutter on the Rallye headlights



I bot my self a co pilot *



I was going for the antenna but why I bot the navigation I really don't know :(

a Quattro gearbox





and an MC from Audi TT RS 25.4 mm clip 





Moore new parts

I was thinking for a very long time what to use for my gearstick and this is the answer





R pedals 



Clutch cylinder



Front Audi TT RS brake lines :banghead: I tough they were steel braided but I guess I will be buying Braided ones :(



the pads for Brembo handbrake calipers



finally the MC with the brake fluid tank and the Clutch pump



I also bought a set of 4 Audi RS4 injectors which I will use with the stage 3 or 4 ;D when I buy an engine of course   :D



I also got my garage a little fixed up and cleaned ;)



OK so here is some work done. Finally we started painting :facepalm: The interior and the engine bay have been painted and in the next few days so should the outside ;)











And some more parts:

APR HPFP



Audi S3 IC



and a NS MKV Offset Dashpod from ECS



Audi R8 fuel pressure valve



Audi Oil Cap



and the first thing I will change on my 2.0 TFSI




also updated mu garage with looks and some tools ;)











The only thing that wories me is the size of the IC. It's a bit taller then the Rallye IC ?



but I think I'll find a solution :dontknow:

Finally :D Some paint and clear coat





















Only one thing I have to say:
Just the naked eye can see the real beauty of the finish :cool:

[2fast4you]

Also sone more parts arrived:

I bought NEW all possible screws



and a special ??? thing that goes underneath the fixing points of the front fenders



and another styling detail



Finally after 10 months the Rallye is back in my garage;)









I didn't know where to start :rolleyes: I was all over mu garage taking out the parts stashed for the Rallye







Well the assembly has started :)






And tinted the windows





More parts from the shopping list have arrived

OMP Steering wheel



My racing shoes Alpinestars



Carbone Lorraine brake pads for my rear Camaro SS Brembo Calipers



and some more parts from the VW dealership



The bumpers, rear view mirrors, front grill came back from painting :cool:













I decided to chrome all mu nuts and bolt so here are some of that:



and more new parts







then started cutting the MK5 dashboard ;)





and at the end I finally installed the brake lines  :thumbup:









I painted the front lock carrier, lower cross member and completed the front end and the bonnet because I couldn't wait to see how will the car look at the end











I got the bolts and nuts from the roll cage and the door locks chromed :)



bought some cardan  shafts (Golf Mk5,Golf mk4,Audi TT 8n)



and glued the dash back together





and then cut and glued the other parts that needed fitting

[2fast4you]

and at the end how should the interior look like





only maybe without the navigation ;)

Well finally I received the last batch if nuts and bolts that went to chroming



and so the work can continue   

mounted the front and rear axle, and started on the measuring the propshaft











so everything looking good :rock:

Made the propshaft bolt on the original Rallye propshaft holders ;)





I also did a little intervention on the rear axle because the propshaft was a bit off center :banghead:



then unscrewed the fenders and put a special plastic sealant strip that I bought from the dealer





and then screwed them back on with the new screws and special intermediate zinc plates (they are used so you don't scratch the color ;) )



then installed the drivers seat :) . The codrivers will have to wait because I haven't received the seat rail for the seat :banghead:



after all of that I assembled an BWA engine that I had in mu garage with the quattro gearbox and fitted that on the Rallye







there is enough space for a GT3076 I think



and from under the car



there is one problem that will need to be solved :rolleyes:
the gearbox as fitted is very close and will hit the front axle



and when the car will be on its wheels ...should look something like this:



then the oil pan will be around 11sm from the ground Dont know if it will be a problem



as you can see its almost the same height as the front axle

The lower engine mount finished





and the roll cage painted and half mounted :D







Still waiting for the big update :banghead:

And finally :D:D:D:D:D:D:D
My big update :D:D:D:D:D:D:D

Today I bought this:





a 2010 Seat Leon Cupra R

and the hart for the Rallye





Today I did little work on the engine, because he had same damage:(
Changed the intake manifold mounted the APR HPFP and valve ....











Nothing much done on the car at this time
I tried to clean the gearbox but couldnt so I sandblasted it ;)





installed a new hydraulic clutch pump



then installed the gearbox on the engine and in the car it goes





I started conecting the water hoses and other stuff to see what needs to be modified and when I came to the gear selector
I had to drill some nasty holes to get that thing in the right position and length. I used the Audi TTs gear selector because as far as I know it has the longest cables











and it will be tight on the front end but I think I will manage to get the S3 IC and water cooler in there. If the MK5 GTI water cooler fits in there I was thinking of ordering the Mishimoto one and the Mishimoto fans







SORRY IF THE TEXT DOESN'T MAKE SENSE BECAUSE THIS IS COPIED FROM THE POSTS OF ANOTHER FORUM... BUT I HOPE YOU LIKE MY BUILD !!!

[markymark]

  Awesome work, cant wait to see the end results!

[jameelno1]

  this cars gonna be stupidly fast nice bit of work there 

[edd666999]

  just 

[xjscx]

Awesome 

[sub39h]

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