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My Bora R-Line -- The End -- New Build Thead


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#1 callum_tdi

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Posted 24 June 2011 - 02:15 PM

my R-line bora build
how it looks to date

20140621_130752.jpg

current modifications
Engine + (bay):
upgrade turbo from 150pd
front mount intercooler + piping
EGR delete
panel air filter
uprated clutch + single mass flywheel
straight through exhaust + decat
custom re-map estimated 200bhp 310 ft-lb
battery relocated to boot
screenwash bottle relocated to boot
power steering res relocated
tucked/shaved wiring
A/C deleted
engine spacers
various painted engine parts
poly engine mounts
Bmw fuel cooler

Suspension + running gear:
Ap coilovers
uprated anti roll bars front and rear
upgraded subframe
upgraded wishbones
upgraded hub assembly
custom upgraded rear axel
fully polybushed (every bush)
solid alloy subframe mounts
312mm front brake upgrade
256mm rear brake upgrade
upper and lower front strutbraces
R32 quick rack (steering rack)
steel belly pan
rear camber shims
20mm rear spacers
10mm front spacers
wheel stud conversion
Banded T5 steels

Exterior + body:
genuine R-line front bumper + grills
genuine R-line rear bumper
honey combe grill
anniversary side skirts
Oettinger boot spoiler
cupra R chin spoiler
painted mirrors
black badges
custom headlights
tinted rear lights
tinted side indicaters
vinyl wraped roof + b pillars
pressed plated
Black boser bonnet
Arch extensions

interior:
boost gauge + pod
aftermarket head unit
custom door cards + speakers
amp and subwoofer in boot
interior retrim (camo)
infloor lighting
net optic brushed alloy trims

car came originaly fitted with
factory parkins sensor, cruise control, 6 disk cd changer, centre arm rest and all the usual
had 52,000 on clock paid £2500
bad start my neghbore
hit my car the other night aparently not drunk
DSC00043.jpg
well least it gave me some insentive whilst it was in the body shop
DSC00136.jpg
back from the body shop just waiting to get the last grills and fogs
DSC00149.jpg
then thought i wold colour code the engine covers
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DSC00150.jpg
got my new wheels now also withe last grills and fogs fitted and working
DSC00169.jpg
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waing on my boot install to come back from the upholstery place at moment then can put some more pics on
oo just remembered iv got a sneeky pic of install befor it went for upholstery
http://i1211.photobu...-10_1137031.jpg
rearly need some r32 side skirts
wat u think so far




#2 callum_tdi

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Posted 25 June 2011 - 03:29 PM

 had to go to upholsterers today to check the colour of the leaterett vinle for the boot install so it matchs the interior but wat do u know theyve ordered the wrong colour[clap] wounderhow long iv got to wait now



#3 callum_tdi

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Posted 02 July 2011 - 02:38 PM

 saturday has come so the bora gets a clean, polish and wax

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#4 callum_tdi

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Posted 02 July 2011 - 02:43 PM

 thats my nephew and daughter being lazy wilst i do all the work

police didnt seem to like my rear lights so had to get some stupid reflectors[paperbag]

and more clean shots

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#5 callum_tdi

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Posted 02 July 2011 - 02:44 PM

 Posted Image

chrome is allot of hard work



#6 callum_tdi

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Posted 10 July 2011 - 12:44 PM

 finally got my sound system back from upholsterers this weekend [<:o)] so pleased withe overall finnish

got all fitted know and islooking good

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#7 callum_tdi

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Posted 10 July 2011 - 12:58 PM

 dont know wat the missis is on about still plenty of boot space[*-)]



#8 AJPTDI

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Posted 10 July 2011 - 01:12 PM

Quite like the bumper, although some purists might not! Agree that you need some R32 sides. And if you can split the headlights to paint the innards black that would finish the front end nicely.

#9 callum_tdi

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Posted 10 July 2011 - 01:20 PM

 yeah know wat u mean about the lights, inpro do some allread black look completly oem good price to all in the pipe line lol


thanks for comments


 



#10 callum_tdi

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Posted 13 August 2011 - 11:32 AM

thanks to imagewerks finaly started my door builds thought id use the same method
using snap-on plastic welder
DSC00204.jpg
DSC00203.jpg
DSC00205.jpg
started by unpicking all the melted plastic that holds every thing together but not removing it sinply shaping it to fit back through the hole so it can be reused for reassembly
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then removed the cloth section the same way
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then speaker grill
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then along with the top section
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once all apart can start working with the peices first up is shortening the door pocket on the main panal to make room for the speakers
DSC00215.jpg
then of coarse is shortening the actual pocket
cut to size to match the opening then welded together
http://i1211.photobu...di/DSC00212.jpg
when it is holding nicley added som reinforcment grid/mesh and melted in
DSC00213.jpg
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now i cut the baffle for the speakes to mount out of some 12mm mdf
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then shape the door slightly for the baffle
DSC00216.jpg
once shaped using some scap mdf and hot glue gun mounted the baffle to the door
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then when its all cold and set mask up all the inside of the build
DSC00225.jpg
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then u can start working with the expanding foamjust used cheap homebase sff nothing special
DSC00227.jpg
spray a fine mist of water over the work peice to begin as this chelps the foam to set get in all the tight spots first then build it up all around
[Img]http://i1211.photobu...di/DSC00228.jpg[/img
DSC00229.jpg
next steps
cut excess foam and shape
aply fibreglass resin let set
light sand
then skim of filler and sand
then a couple of layers of fibre glass mat reason for first skim of fillef is so ther is no air bubbles uner the mat
then re skimm with filler then off to upholsterers for wraping

#11 Imagewerx

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Posted 13 August 2011 - 11:40 AM

Phwoooooaaarrrrr that is pure hard core foam porn[heat],Kleeenex anyone[:DD]?



#12 madman

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Posted 13 August 2011 - 11:49 AM

loving this build...the boot looks very tasty. Im watching with interest.[C]



#13 callum_tdi

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Posted 13 August 2011 - 11:51 AM

 thanks alot been planning on doin this for ages seeing urs imageworks just gave me the push



#14 pchende

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Posted 13 August 2011 - 12:04 PM

Really good build, any links to where you got the front bumper front, really like the look of it [Y]



#15 nickbrapp

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Posted 13 August 2011 - 12:16 PM

this is brilliant, i want a honeycombe grill, i would change the wheels and it would be spot on



#16 Imagewerx

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Posted 13 August 2011 - 01:09 PM

Good idea on re-using the plastic lugs which beats my angle grinder method [whistle],front end looks nice and good to see something different with the polished Audi wheels[clap].


Chris.



#17 bigginge

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Posted 13 August 2011 - 01:53 PM

purly awsome bud love the fact its different love the bumper bud just could do with some lows lol spot on mate 



#18 callum_tdi

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Posted 13 August 2011 - 03:21 PM

 pchende


heres a link to the bumper might still be onofer price but unsure


http://www.jkautospa...trich_concepts/


nickbrapp


the grill is from 06 polo gti wont fit bora bumper though, every one to there own i supose on the wheels


imagewerks


 thanks for the coments,yeah i liked them cos there different two was looking at wheels for ages then found them by accident


bigginge


dont talk to me about the arch gaps its rearly anoying cant lower at the mo though as wont be able to get into my work carpark let alone get it into our work shop


have to wait for the air ride then no probs 



#19 callum_tdi

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Posted 13 August 2011 - 03:34 PM

 little update started shaping the foam on the door card but as allways it got to dark to carry on

 Posted Image

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heres a pick of a near finnished drivers side but thought id show how i got there with the other side

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#20 Imagewerx

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Posted 13 August 2011 - 05:30 PM

Coming from someone who now can't open his glovebox properly[whistle],do you still have full seat sliding with them sticking out like that?



#21 bigginge

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Posted 13 August 2011 - 05:53 PM

ha yeah cris ur door pods r awsome id sacrafice the glove box as well


 



#22 Imagewerx

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Posted 13 August 2011 - 05:56 PM

That reminds me to put another coat of textured paint on mine before [|-)].



#23 callum_tdi

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Posted 14 August 2011 - 04:21 AM

Coming from someone who now can't open his glovebox properlyWhistle,do you still have full seat sliding with them sticking out like that?

yeah should be ok mocked up the baffle to the actuall door and the only thing that looks close is the up and down lever on drivers seat supose i could shorten that if it became a problem so should just have the glove box prob but thats liveable dont think iv used it any way lol



#24 C1ayton89

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Posted 14 August 2011 - 04:36 AM

Looks good mate cant wait to see it finished :)



#25 callum_tdi

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Posted 14 August 2011 - 02:40 PM

 heres a little pic for chris tested the panal to check the clearence now its together started to get paranoid after u mentioned lol

 this is with the seat further foward than my driving position so it looks fairly clear

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and another

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a little progress today first layyer of resin then skim of filler with a bit of shaping just so theres less chance of air bubbles between foam and matt

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its so hard to try and replicate a shape without a mould but think im getting there

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now with two layers of fibreglass matt ripped not cut as i find it shapes better but forgot to take pic untill i had added a heavy skim of filler

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been using 40 grit emery cuts through filler like butter and dont have to worry about scoring as there being wrapped in vinyl and not painted

trying to get a passat cc finnish on the interior with two tone beige/black



#26 Imagewerx

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Posted 14 August 2011 - 02:52 PM

Good work so far,a pair of 6s seem to look neater than a single 8in.


Am I to assume that you're fixing the speakers to this rather than to the nice solid inner door skin?


Chris.


P.S. 40 grit FTW[clap].



#27 callum_tdi

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Posted 14 August 2011 - 03:04 PM

 yeah 16 cm speaker 145mm cut out yeaqh mounting to this


you like me 40 grit then lol so much easyer when u havent got to paint



#28 Imagewerx

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Posted 14 August 2011 - 03:12 PM

yeaqh mounting to this

You know it'll resonate like a biatch and colour the sound a LOT don't you mounting them like that? That's why the best sounding speaker cabinets aren't made from cardboard and 3mm thick plastic.

Chris.



#29 callum_tdi

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Posted 14 August 2011 - 03:26 PM

 arh should be ok plenty of people have made builds like this even seen about 10 speakers on one door still sounded good, will prob get allot of deadening in there though


its only for personal use though so not gonna be entering any sound offs or competitions so not to worried


loving the grape thread most random one iv ever seen



#30 Imagewerx

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Posted 14 August 2011 - 03:34 PM

 arh should be ok plenty of people have made builds like this even seen about 10 speakers on one door still sounded good, will prob get allot of deadening in there though

its only for personal use though so not gonna be entering any sound offs or competitions so not to worried

Mine is also just for personal use,doesn't make it right just because every one does it like that though.How about building some sort of enclosure behind both of them so they only use the airspace in between the inner and outer door skins,just like the original speaker does?

Chris.







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