Tuck&Poke's build thread

[mgpdoc]

We need moar.

[kittenpuncher]

Superb thread, attention to detail is spot on.

[Tuck&Poke]

I might take it to this local show called Nurotag this weekend, so I'm getting it ready to drive in preparation for that, the assembly has begun.

I went to a local fittings store to buy this coolant fitting for the turbo. The old was got nicked once while removing the turbo and will probably never seal right.



One doesn't just simply go to a fittings store for one fitting. Of course I thought of other stuff to buy while I was there. :



I wasn't a fan of the previous clamp, plus it didn't really clamp as it was meant for a bigger sized line. This one fits nice and snug and its black.



Also bought stuff to make the new coolant line from the block to the turbo.



The weld on fitting and barb adapter are for the current overflow line, I will of course make a nice one out of braided hose soon enough.



Started final assembly only to realize I'm missing the nut from one of my downpipe V-bands, so I placed an order for one. Also finished wrapping the manifold.



Took a trip to the dealer and ordered almost $300 worth of little parts and screws :'( One of my purchases, had to cut it up to fit the intercooler before it even saw sunlight. The other side has been special ordered.



No fogs





Bung welded to the coolant bottle.



The replacement skirts for the set I trashed came in.



Mandatory test fit even though I've pretty much always had these on the car at some point. Rear skirt hopefully gets mounted this week. Car doesn't leave the garage till it's on.



Dropped the rear some more, but it looks like I'm gonna have to take out perches to be satisfied.

Cleaning up the wheels. Haven't seen a polishing rag since the motor build started. They've definitely got some stains still but its good enough for now. I'll care more when the paint is done.





X-mas presents to myself.




Roof spoiler and a new lip. That means I have everything I need for the exterior to paint the car. Now I need to pick a color :-\

[Tuck&Poke]

Some stuff I've been working on lately. Since the car is stuck in my garage I can tinker with it a few hours a day after work. So here is all my tinkering.

My box from full race came in. Iconel steel studs with silver plated nuts and anti-vibration lock washers. I was gonna drill the studs out to put a cotter pin, but I want to give these washers a try first.



My battery box in the trunk. Jared made it for me but I'm not sure I want to run it. I'll leave it for now but I'm gonna try to hide the battery instead so the trunk looks stock.



I've also been tidying up the interior. Replacing any missing screws or covers with new OEM pieces.



The headliner came back from the upholstery shop. I didn't want to go with the typical suede for a more OEM feel. I forgot to take more pictures of it but I'll get some up.



The Skoda vents in the new dash.





Net optic ash tray sanded down to a brushed aluminum finish, and RS4 shift knob, need a boot for that. I'd like to eventually replace the wrap with real carbon.



I love the Passat cluster. AWE boost guage with a new south pod. I **** it because the cover squeeks. Its a shame they don't make the 42dd pillar pods for the Passat anymore.



The knee panel is kind of a pain in the ass to install properly, but its in there with all the proper clips and screws.



Haven't had these pieces in like 5 years, finally picked up a pair from the dealer.



New plugs from the dealer as well for the kick panels.



The wheel again just because I love it.



You can see the headliner in this pic too, I need all the black headliner parts.



Ive been trimming the bumper to fit now as well. Now that the intercooler is polished I don't want the bumper rubbing on it and marring the finish.



The body guy is gonna clean it up nice when it gets sent off to paint. Still want to trim a little more just to make sure it won't rub.



The bumper fits MUCH better now. This side was sticking out the worst. Once the bumper is on properly I can mess with the headlights a little more to get the fit perfect.



It's still not great, but considering it isn't held in by any screws right now it's pretty good. I'm going to continue to tweak it. I think I need to buy a new fender bracket, I fear the OEM one is bent.



This side is better.



There aren't any screws holding in the headlights right now so thats why it sags

Cleaning like a madman in here.



You can see where the paint is burnt from all the heat in there. The ceramic coating and thermal wrap should help. I'll also gold foil that part of the frame rail.



Started wrapping the manifold but I ran out. Gotta get another roll and some ties.



Downpipe wrapped, need ties for this too.



The brace for the turbo manifold.




New wheel on the turbo, all cleaned up and ceramic coated as well.







More cleaning. This was filthy, couldn't even see the paint.







With the bare manifold it would get so hot that this coolant line melted, even with fiberglass shielding.







New to me back bumper. The other had a nice hole in it from my lovely neighbor's tow hitch. This one will be an easy fix for the body guy.





These are in a bag somehwere in my garage.....

[Tuck&Poke]

More shiny shit came in. Too bad you won't be able to see any of it under the heat wrap.

[Tuck&Poke]

hey jahn

[BananaClipArnold]

hey jahn

[Minuki]

I'd totally forgotten about this car. Good to see you still have it and doing great work!

[PoLonY]

Awesome car!

Love it

[andybob]

Was wondering about this the other day. Nice fab work and everything. Nice to see some of the OG's still at it.

[Tuck&Poke]

Sent intercooler stuff to the polisher and got it back a few days ago. I got bored one night after I ran out of trees to smoke so I started putting it together



The fucking ding on that pipe is driving me NUTS, but there's nothing I can do for now. Luckily its not very visible with the clamp in place.



Got the clamp polished too.



Now I need to trim the bumper to fit the intercooler. Started already and it fits much better.




Remnants of the oil leak on the turbo and burnt paint. Gonna clean it up some today. All the hot shit, including the turbine housing, manifold, and downpipe are now off and getting ceramic coated. Turbo is getting a new comp wheel and thoroughly cleaned. Then once its all back it will be wrapped in fiberglass insulation to further reduce heatsoak.

[Tuck&Poke]

These are all from before sowo 2013 so bare that in mind


Ok so some more updates. Trying to rush to get the car started this weekend and driving by next week. I need a decent amount of time to drive the car and break it in and iron out any kinks before Sowo.

Without fuel I won't be starting anything, so I finally had to sit down and figure out how I was gonna tackle that. The 034 didn't end up fitting in the tank, so plan B was either a surge tank, or just inline. Surge tank is a bit expensive and I'm always weary of them as I've heard you can have cavitation issues, so I decided to just do it inline. The stock pump will feed the 044, which will then create the fuel pressure.

First things first, since I'm using rivnuts to mount it under the seat I had to drill out the holes on the bracket



All braided hose back to the factory rubber hoses that feed into the tank



Used a few clamps to secure it to the body



Did the ECS stainless steel brake lines while I was back here





Used the integrated engineering fuel filter that comes pre-fitted with -6 fittings and mounted the pump



Finished making all the hose and secured everything.



Also finally finished the intercooler. None of the pipes stick out past the grill



Also raised it a little. Still needs to go up a little more.



From when it was first running, since then its been disassembled again to get some stuff done that I rushed to make it to sowo.





Had to raise the rear a bit because on the first drive it was billowing smoke on the highway. This is a little too high though.

Someone stopped me and took a pic of the engine bay at sowo

[Tuck&Poke]

Guess I can update this again for anyone interested haha

Folded up some aluminum











Then Jared welded them to the intercooler







Mounted. Nice and stealthy.



Next up is figuring out how to get this fuel pump to mount. I bought the 034 Motorsports billet fuel pump bracket for the bosch 044 pump

Pump didnt come with a pre-filter, so we came up with something to mount the stock one to the pump, but I gotta wait for him to make it on the lathe.





Also started bending line for the abs relocation

First time we use the bubble flare tool















And an old picture from the ride up to H2O

[/QUOTE]

[NeedingAnAudi]

Wait a sec, you haven't cut reliefs for the upper control arms and you're at that height?

[T B W]

That loom is beautiful wrapped like that. Wanna do mine?

Loving this and cant wait to see what the future holds