Golf Rallye 2.0tfsi+haldex gen2

[tuner4vag]

Hello everyone this is my first thread so please excuse any mistakes.
Anyway i want to show my "baby" and the work stages so far.




this is how i bought the car.Its been turned into a van by its previous owner :shake:

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0057.jpg

and it was used to carry animal food and farm tools so mostly driven on dirt roads :shake:

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0056.jpg

until this rear side accident stopped the torture and came to me to save it from the scrapyard :thumbup:

[vwgolf1]

Looks like a load of work!
Any of the work done jet?

[tuner4vag]

A lot of work ? yes but enjoying every minute

now a little update some pictures from the work progress until today

2 months ago

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0238.jpg

the used rear left wing is welded on

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0239.jpg

a bit of rust on the floor but repaired properly

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0240.jpg

after that the car came to my place and i began to strip it to the bone

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0247.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0248.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0249.jpg

i found that it had a mercedes exhaust on

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0246.jpg

[tuner4vag]

1 month ago , more stripping

http://i1239.photobucket.com/albums/ff501/tuner4vag/014362011.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/015362011.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/016362011.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/017362011.jpg

the result is a place full of parts

http://i1239.photobucket.com/albums/ff501/tuner4vag/018362011.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/019362011.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/020362011.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/021362011.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/024362011.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/025362011.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/026362011.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/027362011.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/028362011.jpg

this is what we changed to the front suspension domes ,vw polo '00 parts

http://i1239.photobucket.com/albums/ff501/tuner4vag/023362011.jpg

the front top mounts that i will be using are not wearing off so quikly and the turning at low speed is much improved , hopefully

http://i1239.photobucket.com/albums/ff501/tuner4vag/022362011.jpg

[ws4eva]

Nice. Great save. We need to get a few of these rallyes over for the rallye meet in the UK.

[Marcski]

wow, good luck with the build!

[HannoverEdition]

WOW!! :eek:

RESPECT! for all the work you did.and have to do! :thumbup:

Good luck with this project!

keep us informed!

[VeeDubber]

Very nice project! Where did you get those sideskirts?

[Rutger]

Nothing but respect. Great you are saving this rallye..!

[tuner4vag]

thank you all for the support.
VEEDUBBER the sideskirts are custom made with 1.5mm iron sheet insteed of 0.8 of the original item.

[tuner4vag]

update time

more rust repaired

http://i1239.photobucket.com/albums/ff501/tuner4vag/029362011.jpg

after many hours of cleaning the body and the mechanical parts,

http://i1239.photobucket.com/albums/ff501/tuner4vag/035672011.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/036672011.jpg

the time came to start the engine bay preparation starting by mounting on an 1.8T block with corrado gearbox on the original mounts to get the right measurments

http://i1239.photobucket.com/albums/ff501/tuner4vag/030672011.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/031672011.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/032672011.jpg

and now after building the jig

http://i1239.photobucket.com/albums/ff501/tuner4vag/08072011433.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/08072011437.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/08072011438.jpg

its time for the 2.0T block with the 6speed quattro gearbox to be hanged on the jig and fabricate the mk5 engine mounts

http://i1239.photobucket.com/albums/ff501/tuner4vag/08072011445.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/08072011442.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/08072011446.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/08072011024.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/08072011023.jpg

perfect aligment for the propshaft

http://i1239.photobucket.com/albums/ff501/tuner4vag/08072011021.jpg

finished the right side

http://i1239.photobucket.com/albums/ff501/tuner4vag/08072011010.jpg

and on to the left

http://i1239.photobucket.com/albums/ff501/tuner4vag/08072011019.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0329.jpg

and done with the left to

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0341.jpg

and the final test

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0343.jpg

with another (complete this time) 2.0T engine with the right gearbox

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0344.jpg

[Tjaap]

that jig is a great idea.. and damn, how many engines have you got scattered around that garage?

[tuner4vag]

that jig is a great idea.. and damn, how many engines have you got scattered around that garage?

do you really want to know???

i will post some pictures tomorrow that will say a lot! ;)

[tuner4vag]

update

a bit of work on the rear axle

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0328.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0350.jpg

[tuner4vag]

the chopping began

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0331.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0332.jpg

complet masaker

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0335.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0334.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0336.jpg

and finally shaved

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0342.jpg

before and after like diet commercials

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0349.jpg

[Tjaap]

is the Haldex that much bigger?

[tuner4vag]

is the Haldex that much bigger?

it is .the damn think is as much as 12 cm longer in the rear end and i will have to cut it out . the idea is from this guy (RESPECT , WONDERFULL JOB)
http://www.dsg-corrado.de/index.php?option=com_zoom&Itemid=46&catid=25
:thumbup:

[Marcski]

please wear some goggles while grinding if you want to keep your eyes ;)

[tuner4vag]

i have over 200 engines in my place and not only that , and for the truth here are some pictures

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0352.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0351.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0366.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0353.jpg

some HALDEX

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0355.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0367.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0354.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0368.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0369.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0371.jpg

a half cut golf mk5 GTI

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0356.jpg

and the AUDI jewel

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0370.jpg

actually i have 3 of these
:)

[tuner4vag]

is the Haldex that much bigger?

check out the difference

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0360.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0361.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0362.jpg

[De Pul]

holy crap mate,you got some bitch-ass collection over there:eek::wow:

[VeeDubber]

looks like a VW-nut's heaven :D
Impressive. You sell parts as a job or is this all hobby?

[tuner4vag]

it's my job , we import spare parts from Germany directly from AUDI and VW and we are probably one of the 5 bigger and more complet parts stores in Greece.
if anyone needs parts from 2005 model V.A.G.s and above feel free to ask.
i dont usualy sell parts outside of the country but with the crisis here i consider creating an ebay store.

[Marcski]

:eek: :eek:

[VeeDubber]

Can you give us an indication of the prices?
For instance what price do you ask for a haldex? Or a R32 engine?

[tuner4vag]

Can you give us an indication of the prices?
For instance what price do you ask for a haldex? Or a R32 engine?


ok. a haidex complete diff with ecu gen 1 ?(golf mk4,S3,TT,leon) around 400euro

an R32 set from AUDI TT 8N including :engine complete with harness,ECU etc. dsg gearbox ,haldex diff ,air filter box , exaust with cat's , driveshafts, cardanshaft , intruments , gearshifter , steering wheel (dsg) around 4500 euro

same parts for 1.8T mk4 180ps manual gearbox front around 4000 euro

same parts for 2.0T mk4 200ps manual front around 4500 euro

same parts for 4.2 S4 B6/B7 344ps automatic quattro 7000 euro

same parts for 4.2 RS4 B7 420ps manual quattro 10000 euro

same parts for 4.2T RS6 4B 450ps automatic quattro 8000 euro

same parts for 5.2 S6 4F 435ps automatic quattro 12000 euro

TTS seats leather 2000 euro

TTRS seats leather 2300 euro

i hope that covers you

[2fast4you]

I didn't realized that you started your project until know :D I forgot about your Rallye :tongue:

Nice work so far :thumbup: .I see you have a TTRS seats do you have an engine??? ;)

[tuner4vag]

I didn't realized that you started your project until know :D I forgot about your Rallye :tongue:

Nice work so far :thumbup: .I see you have a TTRS seats do you have an engine??? ;)

no ,no engine unfortunately the german boys in ingolstad are still testing hard those engines and the cars come without. when i have one believe me everybody in this forum will now :D

[2fast4you]

Any updates :confused:

[tuner4vag]

no updates for now because of the summer vacations and the unbelievable heat in the garage.
hope to begin working again until the end of the month

ohh and after i finish a friends project
http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0391.jpg
A4 '07 1.6 into rs4
http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0392.jpg

[tuner4vag]

hello guys i missed you all.

it was a very hard winter here in greece and it will go on for a long time as it seems (economically speaking) .

anyway time for updates for the work its been done in the past few months.

the rear axle needed to be chopped to clear the haldex http://i1239.photobucket.com/albums/ff501/tuner4vag/30032012493.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/30032012494.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/30032012495.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/30032012496.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/30032012499.jpg

will give more updates soon

[2fast4you]

Why chopped ??? I don't understand ???

[tuner4vag]

Why chopped ??? I don't understand ???
if i place the diff under the axle it sits too low and the propshaft and axleshafts dont allign properly. if you want to see a finished project with the same job on the rear axle check this guys site they are very good at this kind of jobs.
http://www.dsg-corrado.de/index.php?option=com_zoom&Itemid=46&catid=25

[2fast4you]

Here is mine:

http://i911.photobucket.com/albums/ac313/golfrallye/1d2874de.jpg
and I don't see anything wrong ;)

[tuner4vag]

I hope everything works fine in both our rallyes when they hit the road. It is my first old model car restoration/transformation project and i hope i have taken the right path. I usualy make original models upgrades like (audi A4 into RS4,Golf 1.4 into GTI, A3 into S3 etc.) so i am used to bolt on work.

[2fast4you]

I hope everything works fine in both our rallyes when they hit the road. It is my first old model car restoration/transformation project and i hope i have taken the right path. I usualy make original models upgrades like (audi A4 into RS4,Golf 1.4 into GTI, A3 into S3 etc.) so i am used to bolt on work.

Well in that case this will be a whole new experience for you :thumbup:

[tuner4vag]

i received the parts from the CNC to make the box that will receive the haldex diff

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0017.jpg

hope i mesured it all correct so the assembly will be easy

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0025.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0026.jpg

this is what the box will look like when the parts are welded together

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0027.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0028.jpg

after the welding job is done we have to make the holes and the threads to receive the diff

[2fast4you]

I think you should reconsider what you are doing ;)
Here is a picture how the Haldex sits on my Rallye :confused: and you lifting it up... I think you will have problems with the propshaft :confused:

http://i911.photobucket.com/albums/ac313/golfrallye/IMAG0523.jpg

[tuner4vag]

the mesuerements i took from the synchro diff before i cut everythink down are exactly as the haldex so if i use a prop with the same size as the original rallye item i shouldn't have a problem . anyway we shall see .

[De Pul]

any updates?

[vdWal.]

wow, cool project!

and what a job, and place full of great stuff :thumbup:

[VinceV]

one word: WOW! :o

I like the built, crazy garage!!! respect!

grts
vince

[Audi1981]

Good project :thumbup: > subscribed :D

[tuner4vag]

thanks everybody for the good words , the project was paused for the summer due to extreme heat and economical resses. i just restart the work and hope to have updated photos soon.

[Audi1981]

Nice to hear :thumbup:

[VeeDubber]

Show us some pics when you have some!

[tuner4vag]

I stole some time this week and i prepared the baseplate for the steering wheel column.

the original one:

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0102.jpg

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0103.jpg

and the original baseplate:

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0104.jpg

the AUDI Q3 part:

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0105.jpg

chopped:

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0107.jpg

and the mk5 column:

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0108.jpg

fitted together and ready to be welded on the chassi:

http://i1239.photobucket.com/albums/ff501/tuner4vag/IMAG0109.jpg

when that is done i will post the new photos

[Audi1981]

Nice :thumbup: Going for a complete mk5 look inside?

[2fast4you]

What happened here ??? Any progress ?

[isj60]

No more progress ?