Madmans' OEM+ Diesel Build 17 Years on! - Members Rides - uk-mkivs

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Madmans' OEM+ Diesel Build 17 Years on!


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#1 madman

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Posted 01 August 2010 - 07:57 AM

[C]INDEX TO MADMANS BUILD

Click links to go direct to the page (needs fixing since forum changes)

 

 

Madmans GTTDI130 spec.

Engine & Ancillaries

Allard EGR delete

DIY fabricated 57mm alloy and silicone Intercooler pipework   

More intercooler and pipework pics here in Sleekys post

1.8t pancake pipe (bigger than PD130) 60mm silicone to intercooler- 50mm silicone to red turbo pipe

godspeed alloy uprated side mount intercooler

80mm cold air feed from lower grille to standard airbox 

link to origional 80mm cold airfeed topic

K&N panel filter

 

Küberl Tuning GmbH chip stage Blacksmoke remap tweaked 

FR&R Tuning STB  Remap currently running fast road map

Raceland decat down pipe

Remus Stainless system (straight through)

Diesel Geek Panzer sump guard (sound proofed with 6mm neoprene)

Powerflex dog-bone bushes

Removed N18 & N239 valves...leaving just the N75 valve

 

Running Gear

O.Z. Arristo R32 alloys 18x7.5 refurbed by CAS coatings in Antheracite- silver fleck

tyres Uniroyal Rainsport 2's   225 40 18  Uniroyal Rainsport 3 225 40 18

Zimmerman drilled discs all round 312mm upgrade front

Greenstuff pads

Weitec Hicon Gt coilover Kit + bushes + bearings

Powerflex rear beam axle bushes

Forge alloy - carbonfibre strut brace

Poly bushed front wishbones

TT Front 20mm ARB

 

312mm 256mm F & R brake conversion 312mm Zimmerman discs

 

DIY maintenance jobs I've carried out

All of the above mods

Cambelt change

Water pump

Water temp sensor

Ancillary drive belt

Thermostat

MAF sensor

retapped (Helicoil) engine mount thread

Cv joint boot...too many times

Arch liner intercooler vent

Delock drivers door

Cleaning the VNT mechanism with Mr Muscle Oven cleaner  

Cleaning the VNT again with mr Muscle oven cleaner

Innotec Turbo clean

312mm brake upgrade

Under body cleaning/ arches de-greased Surface rust treatment

 

 

Interior

Pioneer double din head unit AVH-P3100DVD

Vibe Litebox stereo 2 - amp 

Focal 165VB 2 way component speakers

Pioneer secondary speakers for parrot car kit

Alarm - Dual blue LED's

stripped and polished netoptic trim (full set)

.:R line mats TT pedals

 

Exterior

4 Motion front vallance

 

Miscellaneous

stebel Nautilus compact air horn 130db

Depo black projector headlamps - 6000k HID compact kit   5000k Hid kit Audi projectors fitted in the Depo housings

silvertec indicator bulbs

tinted repeaters

LED sidelights 6kk

Stubby antenna New polo antenna    CELSUS AN3022DAB DIGITAL RADIO (DAB) & AM/FM ROOF MOUNT ANTENNA

 

Car was new April 2002

The car was formerley owned by Allied Grain Berwick upon Tweed Scotland, where it was a reps car. It had full service history at Western VW Edinburgh, with oil changes every 10k and had just under 80K when i was introduced to it.

 

I fell in love with this Golf in 2005...

A mate ( 2nd hand car dealer) lent it to me as my car was off the road. I took it to Croft to watch the Touring cars and was very impressed by it. I asked him how much it was going for and got it for £7500 cash. It replaced a 1994 Astra mk4 1.7 TD the issuzzu engined vauxhall which Id had from 6 month old. It pretty much stayed standard for a long time. I put a set of R32 rims on which were a Xmas present and left it at that for a while ...the more I browsed this forum the more ideas I got. It started with a K&N filter and 80mm cold air feed. I also got a very expensive German tuning box for reasonable money from a mate. Then one day it was down on power and that was traced to a choked up EGR and inlet manifold.  I did the EGR delete and ran it for a while till I finally got a coilover kit due the susspension been rather saggy. It had a full set of zimmerman drilled discs and greenstuff pads put on for the MOT Aug 06....so that was the start of me spending a fortune

 

This was it in its totally origional condition

 

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Then with the R32 rims

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night shot

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Twilight

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#2 madman

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Posted 01 August 2010 - 08:00 AM

Intercooler vents cut into arch liner

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After a paint correction session with a mate of mine...Its gonna look worse before it looks better!

 

Bonnet touched up and flatted down

 

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#3 madman

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Posted 01 August 2010 - 08:10 AM

Duplicated during forum upgrade



#4 Qais

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Posted 01 August 2010 - 10:14 AM

 Nice ride



#5 madman

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Posted 01 August 2010 - 12:31 PM


 

 Nice ride

 

 

 

cheers[Y]

 

Heres a slightly better pic...need to dig camera out as these are all taken with my HTC  phone.

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Sump guard

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Lowered

 

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#6 madman

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Posted 01 September 2010 - 03:40 PM

new item  to go on at the weekend...Remus Exhaust backbox stainless steel

another ebay bargain!

Posted Image



#7 Qais

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Posted 01 September 2010 - 03:51 PM

 car looks great lowered fella



#8 madman

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Posted 03 September 2010 - 01:56 PM

 car looks great lowered fella

Thanks mate yours looks the biz too



#9 madman

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Posted 03 September 2010 - 01:57 PM

Exhaust ready to go on paint stripped off...for the plain stainless look [H]

Posted Image



#10 bowen

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Posted 03 September 2010 - 03:31 PM

 where'd you get the sump guard mate? like the progress so far.



#11 madman

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Posted 03 September 2010 - 03:35 PM

cheers[:)]...took me a while to find, it was  another ebay item. paid @ £60 IIRC bargain!! I love ebay, but you have to be patient...sometimes odd spellings pay dividends[:O]



#12 Djw_Dave

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Posted 03 September 2010 - 03:41 PM

Looks good low mate.



#13 madman

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Posted 03 September 2010 - 03:55 PM

cheers Dave...took me nearly 4 years to lower it. I hated the tractor look.



#14 bowen

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Posted 03 September 2010 - 04:03 PM

 Cheers for the reply mate, just looked on ebay no luck! poo



#15 madman

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Posted 03 September 2010 - 04:10 PM

look for seat leon / ibiza mk1's too



#16 Qais

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Posted 03 September 2010 - 04:53 PM

 car looks great lowered fella

Thanks mate yours looks the biz too

Thanks buddy, but i want it lower



#17 madman

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Posted 05 September 2010 - 11:19 AM

new exhaust back box fitted

Posted Image

size comparison

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looks a bit more meaningfull...and its actually quiter than the standard one.

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axle dropped down to feed pipe over...its pretty tight to get out but the new one slipped in easier

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#18 James120390

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Posted 05 September 2010 - 11:27 AM

 thats nice car dude! does the new pipes make much difference to the  sound?



#19 madman

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Posted 05 September 2010 - 11:59 AM

Thanks


its quieter...there is  no more noise than before. it does seem to rev sweeter too. Not sure if it sounds louder from the outside on a drive-by [au]



#20 madman

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Posted 18 September 2010 - 09:42 AM

Todays job involved drilling out retapping and inserting an helicoil repair thread on the engine mount. Whilst doing the cambelt I found 1 tread totally stripped. which left the engine supported on 1 bolt and one held in with liquid metal, which was supprisingly tightly held.

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Whilst intercooler piping was off it was time for a change. Something a bit smoother flowing!

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Its suprising how restrictive this intercooler to EGR pipe is.When you put the new 57mm pipe at the side of it some of the bends are unbelievable. Heres the origional intercooler connection. which will be removed and replaced with the alloy machined SFS part.

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The parts I got were not an expensive kit but rather ecomomically s elected items from ebay. They do require a bit of cutting of the 57mm 45deg alloy bend. but its easy to do.

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Connection to the EGR 57mm 90 deg silicone bend

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Before

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After...The complete replacement. Looks nice and OEM and flows much better.

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Well impressed with the result all at a cost of ;

2x 57mm 90deg silicone bends                            £22.66

1x 57mm 45 deg alloy bend                                 £19.99

4 x 55mm-70mm jubilee clips                                £2.92

1X alloy adaptor 57mm to VW intercooler            £12.50    This is a SFS item which I purchased off a member ( thanks Dub130)

total                                                                      £58.97

 

A whopping saving over the SFS price @ £133

     



#21 madman

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Posted 19 September 2010 - 02:56 AM

cheap mod perspex fuse box lid

Posted Image



#22 madman

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Posted 25 September 2010 - 02:48 AM

Some pics from my ICE install.

amp test rig

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Vibe Litebox S2 amp in glovebox

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Door cards off to get new wiring from amp into speakers

 

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speaker install with MDF spacer rings

 

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Rear of pioneer headunit

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#23 madman

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Posted 05 October 2010 - 03:46 PM

just thought Id add my 80mm airbox ducting mod pics done about 4 years ago

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#24 Imagewerx

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Posted 05 October 2010 - 03:51 PM

Oi your amp's way too small,how dare you hide it in the glovebox when I have to lose my whole boot  to errrmmm.... hide mine[:P].


Chris.



#25 madman

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Posted 05 October 2010 - 04:00 PM

Ha Ha[:D] shame I cant get a 12" sub in there too Chris...maybe I need a bigger glovebox[:-*]



#26 Imagewerx

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Posted 05 October 2010 - 05:02 PM

http://mobile.jlaudi...hp?series_id=29



#27 Stuart_tate41

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Posted 05 October 2010 - 05:07 PM

Love the idea of the amp in the glove box good work sir!



#28 madman

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Posted 06 October 2010 - 03:47 PM

Love the idea of the amp in the glove box good work sir!

Thanks

 

Chris, what are the chances of ; A- getting them small subs in the back doors

B- making them sound bassy enough

Cheers

 



#29 Qais

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Posted 06 October 2010 - 04:06 PM

Nice



#30 Imagewerx

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Posted 06 October 2010 - 04:13 PM

 Chris, what are the chances of ; A- getting them small subs in the back doors

B- making them sound bassy enough

Cheers Phil

None at all,if you don't want a "proper" sub why not put 8in components in the front doors? Those JL 6in subs are amazing for a cone that size,but MUST be used in the recommended size box,just 0.25 cu.ft isn't much room in anyone's car is it[:D]?

Chris.







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