2l tdi mk5 project.

[ryder2012]

ok so i have a pretty standard 2004 mk5 golf tdi sitting outside. its been remapped by previous owner but not much else done to it.

Now heres the list of changes to come

race seats
harnesses and harness bar
roll cage
sound system upgrade
air induction kit
turbo upgrade
egr/egr delete
new pipework across the board
milltech exhaust system
body kit
respray
hatch pop mod
carbon fiber upgrades.
clutch and flywheel upgrades
R32 or better brakes.

[ryder2012]

okay so first of all i wanted to get the sound system done and out of the way so i have something to listen to when working on other stuff.

so i went with the following parts.

edge 750w active subwoofer
FLI component 225w speakers for front and rear doors
FLI 800watt amplifier
FLI 4 gauge wiring kit and 8 gauge wiring kit
4 to 8 gauge wiring kit
custom made switches for sound system*
standard RNS510 head unit
splice connectors
dual line out converters

* i got annoyed looking fora switched live.

I havent installed the drivers door speaker and tweeter as of yet, so in the video below the initial music is from the stock speaker.

i couldnt really find an easily available switched live for the amps so i made up some switches with leds and used on of the button blanking plates below ashtray to install them in. i added leds for a visual reminder they are on. its tied into the live and negative of the cigarette/accesory socket.





left switch is for the subwoofer
right switch is for the speakers amplifier

3s44g

heres the subwoofer



and speakers

[ryder2012]

Next was the race seats, they're being used with the standard seat belts at the moment as the harness bar doesnt ship till feb and comes in from the states as i couldnt find anyone in the uk that does them.

These where actually a real pain in the arse to fit, i ordered the seats and subframes from FK automotive and the subframes fit the car but not the seat, they said they dont make the subframes to fit the seats....er...what?

well anyone, i decided to make my own sub frames from 1" side and 5mm thick hot rolled steel. they are bolt assembled but will be welded up and powercoated eventually.

heres a few snap shops of the seats installed as i didnt intend on a project thread while making the frames so didnt photograph it as i built them.







as you can see the internal lighting has been changed over to led blue as well. theres also blue led strips in the foot wells, looking to have the vagcom changed to have the footwell lights on with ignition so they'll be on anytime the car is.

[ryder2012]

i've put these on order





Along with a pipercross viper intake system.

The intake system has a carbon fiber heat shield in the pipe work to keep the air cool. will see how it does when it gets installed really.

Next on the list of purchases is a carbon fiber hood and aerocatch hood pin mechanisms.

[JoeDarKa]

Are the pedals going to fit? The accelerator pedal comes from the floor doesnt it?

[ryder2012]

not entirely sure, if not i can always modify the stock accelerator pedal to accept this one.

if it needs modding then it'll be pretty simple to get it to fit with the right angle. they are out of stock form where they was ordered at the moment so will take a while before they arrive annoyingly. only informed it was out of stock AFTER the purchase was made.

[dom069]

Are you actually planning on tracking the car?

[ryder2012]

now thats the question isnt it?

my mate has a vauxhal astra VXR and we decided we'll pit our cars and driving ability to the test when the golf is done. so yeah.

if your asking about the roll cage and harness bar, they are more of a safety thing than for tracking. too many idiots on the road.

[JoeDarKa]

GTI pedals would be the better option.

Wheres the roll cage coming from?

[ryder2012]

havent decided on which roll cage yet. i dont really want one due to the weight but with harnesses and a harness bar might as well

[xjay1337]

I would go for GTI pedals as well IMO. GTI pedals are what are used in the VW Cup cars.. Jetta/Scirocco/Golf etc.
Won't work anyway because floor mounted.
not a fan of the seats personally but look forward to seeing the rest of the build progress. have some nice ideas. 

would personally have not spent any money on the intake bearing in mind that the factory air box is not restrictive at all, could be dollar towards something else. looks nice normally never the less.

[ryder2012]

money isnt a problem for this. also the intake is lighter than the stock air filter also the air reaching the intake should be cooler.

the seats...they was chosen for cost and weight until i can order the actual seats i want for the car. want to install momo daytona evo's in the front. 9.5kg without the subframes. these seats i currently have are about 11/12kg. either way FAR lighter together than a single stock seat lol.

the ordered pedals will work just fine with a little modification to the stock accelerator pedal

[xjay1337]

okay.... just because you have lots of money to spend doesn't mean you need to change everything "just because".
IE the intake, no gains (this is very well proven) but probably a couple of hundred?

good luck anyway man!

[ryder2012]

the intake will have a collective gain. one peice of a jigsaw.

I've got an aim to reduce the weight of the car to a set amount. but given performance upgrades and safety parts, i.e roll cage and harness bar, i need to change some things that may give no power increase, but a weight reduction to compensate for the added weight of the safety parts.

so say you reduce the cars weight to 1000kg but then have to add 200kg in roll cage and harness bar, you swap out the hood and boot for carbon fiber, remove rear seats, change the intake for a lighter one and other bits n bobs and the collective weight reduction will being you back to the desired weight.

thats the main reason, that and noise lol.

performance isnt just raw power, its many things. weight is another one of those things.

[Andy]

You also need to change the brakes on the car