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Franko's Garage: R32 Rescue - Forge FMIC


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#1 Franko180

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Posted 20 July 2015 - 09:45 AM

So after been on this forum since the very early days and getting a lot of help, ideas and parts through it, I thought it was fair to put something back, so this is my first build thread on here.

 

This build is for my R32 "rescue" daily driver and is a look back on when I built it and will go up to the present day and I still have some plans and stuff to add to the car, my parts stash is evidence of that :)

 

So I've been driving MK4s for a long time, I started with a (at the time) 3 year old "R" reg 1.8T AGU, but I don't think I have any photos of it, if I do I'll add them later.

 

I then had a brand new "W" reg 2000 MY 1.8T AGU, which I got rid of 3 years later with 98,000 miles on the clock, I had this car before the days of digital cameras (yes that long ago!) so the pic I've added is a scan.

wm-01_zpsxfv2or3n.jpg

 

Then I had my third mk4, a brand new 2003 1.8T AUQ (same running gear/engine/brakes/gearbox as a 1.8T Anniversary), this car had a bit of extra spec, cruise control, dash CD changer, winter pack and was a great daily car to rack up a hell of a lot of miles in. This car deserves a build thread of it's own as I did quite a lot of mods to it over the years, so I might do a retrospective thread on it eventually.

wm-02_zpskoxygx51.jpg

 

Whilst keeping the 1.8T I also decided I should finally own a V6, but to be different (as I already had a Golf) I went for a Bora V6 4-Motion, which I still have today. This has been a great car and I might pop a thread on here eventually for it:

wm-04_zpsrbmglcfu.jpg


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#2 Franko180

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Posted 20 July 2015 - 09:48 AM

So in 2013 I was still driving the AUQ 1.8T and I had put over 200,000 miles on it, original clutch, original gearbox, original engine and I decided that I'd had a very good run in it but for a daily it might be wiser to move on to another car with less mileage on it. I was wondering what to get and would probably have gone for something like an Audi S3 8P and keep the Bora V6 for weekends and messing about in, but then I stumbled across a project that I couldn't resist.

 

A relatively low mileage (but heavily stripped) MK4 R32 that was right on the edge of being scrapped/crushed, that I knew could be a cool project car to turn back into a daily driver:

wm-02_zps93hfseqg.jpg

 

So at this time, the car's condition was this - no front bumper/grill, no headlights, no seats, no wheels, no engine, no gearbox, some dents, very rough rear bumper, standard exhaust still attached, rear running gear all attached, brakes still attached (luckily really nice conditon OEM front brakes with no lip at all), all the interior still present (minus the seats). The car was looking very sorry for itself but it was easy see that it just needed stuff bolting back onto it, there was no body damage, it hadn't been crashed or stolen and even had both keys.

wm-01_zpsupydcclc.jpg

 

So I agreed a price and bought it and booked it to be recovered home, had to throw my spare 17" TT Ronal wheels on to it to get it back into a rolling chassis:

wm-03_zpseaz89ysn.jpg

 

And then helped get it onto a recovery truck to bring it home to and have a look in the cold light of day and work out what's what:

wm-04_zps4jz3hcwx.jpg


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#3 Franko180

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Posted 20 July 2015 - 09:55 AM

So as a starting point I thought best to clean it out and then assess how much trouble I was in :)

 

The car had some parts thrown in it from when they ripped the R32 engine out, some of which were pretty useful, including 6 coil packs which I kept as spares and some other pipe work, alternator, air conditioning compressor, standard airbox and other bits and pieces that I've now ebay'd off:

wm-01_zpsphsbijhu.jpg

 

wm-03_zpsri4aco76.jpg

 

Immediately worked out that this car had been used to ferry a dog around in the boot a lot as both panels in the boot compartment were covered in dog hairs and were a bit worse for wear they'd also half been pulled off by some tool who removed the rear light clusters. Also this car seemed to have had spent a lot of time in the countryside as there were lots of stones and muck on the carpet and in the boot, also the boot carpet was missing:

wm-02_zpsxxiv2cef.jpg

 

wm-04_zpsxig8aseb.jpg

 

wm-05_zps1nqouql5.jpg

 

wm-08_zpszihv7q9c.jpg

 

wm-09_zpsgus1egka.jpg

 


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#4 Rob136

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Posted 20 July 2015 - 06:16 PM

This looks very interesting. Have you any idea what the end goal is?

 

Is it remaining v6?



#5 MK4_S

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Posted 20 July 2015 - 06:30 PM

looks like there is more info on the r32oc forum here



#6 Franko180

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Posted 20 July 2015 - 06:49 PM

No need to exit this forum and lose site traffic for it :) Updates continue below.


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#7 danpalmer1993

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Posted 20 July 2015 - 07:38 PM

Photobucket and then copy and paste the IMG code :Y:

Great selection of cars and a hell of a read so far!

#8 Franko180

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Posted 20 July 2015 - 08:31 PM

Cheers Dan, having a look at Photobucket.


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#9 Franko180

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Posted 20 July 2015 - 10:30 PM

Right, the bucket sorted, let's have a look then.

 

Suprisingly the car didn't smell badly in this condition, but after thinking about it for about 1 second I realised the next thing to do was just strip it right out and clean everything properly as I couldn't know if that dog had "left his mark" anywhere in that car or not. 

wm-10_zpsebfijqld.jpg

 

wm-12_zpsqpc2nidn.jpg

 

So I removed the carpet and the sound deadening, so I could clean the floor properly with some nice scented cleaner (and also to see if there were any hidden surprises under the carpet/sound proofing). 

wm-13_zps4zh8b4ie.jpg

wm-14_zpssmb3q2iu.jpg

 

Once the carpet was out I decided again that I couldn't trust what the previous owner and his doggy had done to the car (maybe the dog had 'scented' the car, who knows, maybe the owner also did?), so I hired a Rug Doctor and gave the carpet a thorough clean up:

wm-16_zpsovsuv5w0.jpg

wm-15_zpsiecdzkl1.jpg

 

I decided to ditch the sound deadening and replace it with new, again didn't want to risk them stinking like Grimsby docks when summer comes. I also took the instrument cluster out as it would need pairing to whatever ECU I ended up with, but also after having full FIS clocks in my 1.8T and Bora V6, I wasn't going to live with gash looking 1990s style half FIS clocks for long.

wm-17_zpsxanu85mc.jpg

wm-18_zpsnamxexpd.jpg

wm-19_zpsjihqesza.jpg

 

 

 

 


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#10 Franko180

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Posted 20 July 2015 - 10:33 PM

Engine bay clean up:
 
"That's what your problem is!" - no engine. So the engine bay was filthy, I want to give it a basic clean up, but also remove some junk out of it that wouldn't be needed. I didn't photograph it, but I also eventually replaced the scuttle panel later in the build. I bagged the end of the downpipe and removed some of the wiring and put it to one side to stop things from getting wet during the clean up.

 

wm-01_zps6hua6f7w.jpg

wm-02_zpszriirnnr.jpg

wm-03_zpspn7r0i1f.jpg


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#11 Trev69

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Posted 20 July 2015 - 11:25 PM

Nice project and respect for taking it on. Dogs definitely leave their mark in a car. Had a merc clk for sale in work and it stank no matter what we done. Sat for months, people came, looked in it, smelt it then left. Then a guy came to see it in a ropey old discovery with a big slobbery dog in. Took it for a test drive, came back and bought it, never even mentioned the smell.
Good work so far, best of luck with the rest of it.

#12 Franko180

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Posted 21 July 2015 - 08:15 AM

Nice project and respect for taking it on. Dogs definitely leave their mark in a car. Had a merc clk for sale in work and it stank no matter what we done. Sat for months, people came, looked in it, smelt it then left. Then a guy came to see it in a ropey old discovery with a big slobbery dog in. Took it for a test drive, came back and bought it, never even mentioned the smell.
Good work so far, best of luck with the rest of it.

 

Cheers Trevo, this car didn't actually stink, but I wasn't messing about and decided to make sure of it.

 

So whilst working on the car I noticed another nice surprise. The headlining was sagging in the middle on the passenger side over the rear window.

wm-01_zpsk2kplloo.jpg

wm-02_zps9txoql1d.jpg

 

Only one thing for it, strip it all off and see what's up:

I didn't photo all of the stages of this (common theme on my builds, when I get stuck in and forget the camera), but basically some of the sun roof drain pipes had either perished slightly or the VW boys in Bratislava had a "friday afternoon" when fitting the hoses during the original car build in 2003. Either way, I realised there was only one way - rip out and replace the hoses and do something about the sagged headlining.

 

On this photo below you can clearly see water collected on the inside of the rear passenger window, this had to be sorted. Also on the next photo a wet patch on the headlining.

wm-03_zpsyynzcjhp.jpg

wm-04_zpseifs8dzj.jpg

 

So bottom line is that I removed all of the headlining, A/B/C pillars, and sun roof drain hoses so I could clean behind everything, check for any surprises and work out what to replace.

wm-06_zpspdyxihhr.jpg

wm-07_zpsiyurkxrr.jpg


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#13 Franko180

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Posted 21 July 2015 - 08:30 AM

So during the strip down and clean up of the car, I had to start sourcing some of the parts needed to build it back up. This isn't everything as other parts came later and there's stuff I forgot about or didn't photo.

 

Seats, these were temporary (yes not R32 Konigs) but they were all I could find at the time and they were a bargain. A3 leather sports seats, the fronts are very similar to MK4 leather recaros but with some extra features. Rears I think look crap compared to Golf ones, but they weren't staying long term. Pictures here are when they were fitted to my AUQ 1.8T just to get them home, they didn't get fitted to the R32 for a while as I Was still doing work on the interior.
wm-05_zps7uaamsw6.jpg

 

wm-02_zpsnsskjxeh.jpg

 

wm-04_zpsmvrju9gj.jpg

 

Boot panels to replace the "hairy" (dog loved) panels. Also a bonus, noticed the replacement driver side boot panel also had a +12v power socket, the dogged panel didn't. These photos are rough and its hard to see the difference between the dogged panels and the replacements, but they cleaned up well and look fine.

wm-10_zps2xmkkwq8.jpg

 

wm-09_zps6nf7b5ci.jpg

 

Sun roof drain hoses:

 

wm-11_zpsg14iotwi.jpg

wm-12_zpsrahdttum.jpg

Front bumper (OEM and with open grills, to make up for the earlier seats)
wm-13_zpsrlq7wijh.jpg


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#14 GregP

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Posted 21 July 2015 - 09:58 AM

Respect for taking this one on.. there's a fair bit of work to do! Interested to see how it turns out!



#15 Franko180

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Posted 21 July 2015 - 11:23 AM

Respect for taking this one on.. there's a fair bit of work to do! Interested to see how it turns out!

 

Thanks Greg, seems a lot of R32s get broken and the vultures glue bits of them into other mk4 models, makes a change to see R32 parts going back onto an R32 :D


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#16 bl1tz

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Posted 21 July 2015 - 02:31 PM

I wish I could find a r32 shell like that, good work though!!

#17 Franko180

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Posted 21 July 2015 - 02:36 PM

All these nice shiney shiney cars on here and I keep posting pictures of my messed up R32 :)
It will get more shiney eventually, but it's a long way off that, more nasty bits need fixing first.

So time to look at that leaky sun roof which had ruined the headlining.I wondered if the old hoses had any blockage from a build up of 10 years of dust/rubbish, so did some testing.
wm-08_zps0clw1xnr.jpg

 

wm-26_zpsfbmelplb.jpg

 

Not much happening? Blocked!
wm-27_zpsjxoyadkt.jpg

 

Got persistant and years of built up dust and gunk came out.
wm-28_zpswwppscia.jpg

 

The front driver's side also had rubbish in the hose, but not as much
wm-29_zpsjzmcr2ua.jpg

 

 

So anyway removed the old hose and fed through and connected a new hose on the rear left side.
wm-03_zpszn4d0mn0.jpg

 

wm-04_zpstbgyubot.jpg

 

wm-05_zpslwm7uojm.jpg

 

wm-06_zpsuds3p43m.jpg

 

Pulled the old front (blue) hoses through (was replacing all four hoses, better to be safe than sorry)
wm-10_zpscqbpfhud.jpg

 

wm-11_zpshdruxmwm.jpg

 

wm-12_zps5sokgg7o.jpg

 

Old junkers Vs a new front hose
wm-14_zpskn9ojg4m.jpg

 

Worked out an easy way to pull the hose through the very tight 'run' it has to pass through, got a couple of long zip/cable ties and locked them together to make a very long "puller" and threaded it through and then taped it very securely the end of the blue hose on so I could pull it through. Wasn't sure if it would jam or the cable tie rip out as it's pretty tight to pull through.
wm-15_zps3mqiey5r.jpg

 

wm-16_zpsokakumza.jpg

 

It worked..
wm-17_zpssc0a6k3k.jpg

 

wm-18_zpsyrhfpgs5.jpg

 

Decided to PVC tape the end of the hose to the new "nipple" just to give a bit more of a seal, probably not needed but did it anyway
wm-19_zpsq9p1ngkp.jpg

 

wm-20_zpslksbqzay.jpg

Did the same on the passenger side, all new parts
wm-24_zpskmz4fhny.jpg

Old hoses, do all the leaking you want now, in the rubbish bin
wm-25_zpsug4qje3b.jpg


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#18 Franko180

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Posted 21 July 2015 - 02:43 PM

I wish I could find a r32 shell like that, good work though!!

 

Thanks, if you did find one, what would you do with it?


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#19 vwharry

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Posted 21 July 2015 - 05:50 PM

Interesting read so far, keep up the good work mate  :Y:



#20 bl1tz

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Posted 21 July 2015 - 06:01 PM

Thanks, if you did find one, what would you do with it?


Possibly restore it (my current car has the urge to become a r32 so I have a few parts already) or the other option is to stick a different engine in there, something along the lines of r36

#21 Franko180

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Posted 21 July 2015 - 09:06 PM

Interesting read so far, keep up the good work mate  :Y:

Thanks Harry, updates are coming..

 

Possibly restore it (my current car has the urge to become a r32 so I have a few parts already) or the other option is to stick a different engine in there, something along the lines of r36

R36 is a great engine, but depends how "right" you want to do the installation. A lot of R36 signals go through CAN bus even things like lighting and the fuel gauge that are simple analogue on the MK4 platform and you'd probably need two wiring looms, some type of mixture of the original loom and the R36 loom. Also they never really got mass produced as much as the 3.2 did so didn't become common enough to get hold of. A lot of hassle for 50-60 BHP but yes it would be nice all the same.


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#22 Franko180

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Posted 21 July 2015 - 10:33 PM

So.. The excitement, erm... Next thing, I changed the aerial, first of the OEM upgrades.
 
The headlining was off and it was easy access, a quick job so got it done.
I upgraded the aerial in the likely hood I'd eventually fit a navigation head unit to the car. I decided to stick an original MK4 OEM Triplex antenna in, pretty straight forwards with no headlining. 
 
wm-01_zpsarnwkgdg.jpg
 
wm-03_zpsiyufs4fw.jpg
 
wm-02_zpsrjgmtthv.jpg
 
This pic is trying to show a subtle detail just for anyone who might do this, the Triplex antenna is a different part to the standard antenna. I'm not sure what happens if you try an "it'll be alright" job on it and force the standard antenna into the triplex base, bad signal or even cross threaded world of fail? :)
wm-05_zps9anlqxtx.jpg
 
wm-04_zpszvvbf05m.jpg
 
Running the GPS cable however was a bit more tedious, I didn't photo it but I ran it all along the right side of the roof behind the curtain airbags and down the A Pillar then under the back of the dash to reach to near the headunit. I secured it to the roof with tape here and there to hope it wouldn't tap/rattle, but the VW way would be to foam it I think. Either way the foam eventually persishes and the tape probably will also over time, so I just did what I could.
 
Done:
wm-06_zpsdb3uzko3.jpg
 
Looking back I wish I'd used a more modern shark fin to give a DAB feed also, this is something I might come back to eventually.

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#23 Kyle_TDI

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Posted 21 July 2015 - 10:37 PM

Awesome mate,

Would love to do something like this. Just don't have the space/time.

Must be ace knowing how much of this car youve put effort into.. It's genuinely yours if that makes any sense?


Kyle!

#24 Franko180

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Posted 22 July 2015 - 08:26 AM

Awesome mate,

Would love to do something like this. Just don't have the space/time.

Must be ace knowing how much of this car youve put effort into.. It's genuinely yours if that makes any sense?


Kyle!

 

Hi Buddy, glad you like it. I'm not one of those people that go on about "built not bought" as there's nothing wrong with buying something that's had the work already done, life is short and you can spend that time on something else if the car is sorted how you want it in the first place. But it is nice to do this and do it approximately how I want it, I cringe a bit when I see people chopping about with relatively rare/special cars, I can always come back to the fact that the car would have been scrapped if I hadn't taken it, so even if I'd painted it purple with yellow spots and put a 50cc motorbike engine in it, it's still better than it being crushed and lost forever :)


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#25 Franko180

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Posted 22 July 2015 - 08:48 AM

So the interior was all still out and it means easy access for any wiring. Not really any good pictures but I fitted a fairly standard aftermarket amp wiring kit in whilst the interior was out, to save any battles doing it later. Main thing here was that the route for the thick +12V power cable goes through an OEM grommet through the bulkhead and was very secure and tight, so hopefully won't end up with a a mysterious wet carpet in in the near future.
 
Glove box out
wm-02_zpsk7bof243.jpg
 
 
Power cable through to the engine bay
wm-01_zpscgpkogge.jpg
 
 
Power cable routing secured
wm-03_zpsswmrras3.jpg
 
 
And pulled through to the rear compartment
wm-06_zpsviaosfkh.jpg
 
No plans to fit an amp / sub woofer and full on system as I need the boot space, but you just never know, so whilst the car was in bits, was rude not to add the wiring.
 

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#26 DIDDY

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Posted 22 July 2015 - 07:05 PM

Looking forward to the updates.

#27 Bullit

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Posted 22 July 2015 - 07:29 PM

Really liking this, we'll done for taking in the less obvious choice!

#28 GTiJON

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Posted 22 July 2015 - 11:24 PM

Nice to see someone actually putting one back together rather than ripping it apart to make some cash. Keep up the work I will be watching this with interest. Do you plan on putting an .:R engine back in?

4175a17f-071d-439b-a5c4-87a6de40bc1f.jpg


#29 PokerProTDI150

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Posted 23 July 2015 - 01:13 AM

This is a nce project, a good chance to make something special.


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#30 Keith Belgian

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Posted 23 July 2015 - 06:02 AM

Great thread.. cant wait to see more of the progress






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