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Mark 4 VW 1.8T GTi Build - RallyCross - MF Class

Posted by DanielSL 
DanielSL
Daniel
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Location: Vero Beach, Florida
Join Date: 03/02/2016
Age: Midlife Crisis
Posts: 304

Rally Car:
2005 VW Mk. 4 Golf GTI 1.8T


Re: Mark 4 VW 1.8T GTi Build - RallyCross - MF Class
December 28, 2016 09:42AM
5 speed transmission mounted, and the engine starts to go in. We were able to keep the Audi TT downpipe, instead of having to buy the custom one for this application; that is only built by one company, and costs over $500.00. This also allows us a nice smooth bend, and the ability to run the TT catalytic converter with the O2 sensor bung. At the slip on clamps, I am going to run a 45 or 90 degree adapter, and run a straight pipe to exit just in front of the passenger rear tire.
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Attachments:
open | download - Mk. 4 on Rack.JPG (50.4 KB)
Mk. 4 on Rack.JPG
open | download - Mk. 4 Brake on TT - LCA.JPG (41.4 KB)
Mk. 4 Brake on TT - LCA.JPG
open | download - Engine Install 01.JPG (54.2 KB)
Engine Install 01.JPG
open | download - TT Exhaust.JPG (37.1 KB)
TT Exhaust.JPG
DanielSL
Daniel
Godlike Moderator
Location: Vero Beach, Florida
Join Date: 03/02/2016
Age: Midlife Crisis
Posts: 304

Rally Car:
2005 VW Mk. 4 Golf GTI 1.8T


Re: Mark 4 VW 1.8T GTi Build - RallyCross - MF Class
December 28, 2016 04:10PM
Engine installed, and shifter hooked up and adjusted. Fired it and ran for a few seconds. Now to reprogram the cluster to the TT's ECU, and program out all of the emissions parts and bits we are removing.



Edited 1 time(s). Last edit at 12/29/2016 10:38AM by DanielSL.
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Attachments:
open | download - Engine Install 02.JPG (61 KB)
Engine Install 02.JPG
open | download - Engine Install 03.JPG (62.9 KB)
Engine Install 03.JPG
open | download - Engine Install 04.JPG (61.3 KB)
Engine Install 04.JPG
Pete
Pete Remner
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Location: Cleveland, Ohio
Join Date: 01/11/2006
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Re: Mark 4 VW 1.8T GTi Build - RallyCross - MF Class
December 29, 2016 10:36AM
I don't think I've ever seen a Volkswagen anything with an EGR valve.



Pete Remner
Cleveland, Ohio

1984 RX-7 (rallycross thing)
1978
Silence is golden, but duct tape is silver.
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DanielSL
Daniel
Godlike Moderator
Location: Vero Beach, Florida
Join Date: 03/02/2016
Age: Midlife Crisis
Posts: 304

Rally Car:
2005 VW Mk. 4 Golf GTI 1.8T


Re: Mark 4 VW 1.8T GTi Build - RallyCross - MF Class
December 29, 2016 10:38AM
Correction: I meant emissions, and I was just typing too fast, after a long day.
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SideburnsSteve
Stephen Hollema
Junior Moderator
Location: Alliston ONT CANADA
Join Date: 01/18/2016
Age: Settling Down
Posts: 44

Rally Car:
yes please


Re: Mark 4 VW 1.8T GTi Build - RallyCross - MF Class
December 29, 2016 12:17PM
Easier is to just get the ECU immo defeated. Local guy does it for 40 bucks for me
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DanielSL
Daniel
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Location: Vero Beach, Florida
Join Date: 03/02/2016
Age: Midlife Crisis
Posts: 304

Rally Car:
2005 VW Mk. 4 Golf GTI 1.8T


Re: Mark 4 VW 1.8T GTi Build - RallyCross - MF Class
December 29, 2016 03:12PM
Stephen, that is what I mean by reprogramming it. We did the immobiliser defeat today. Got it running good enough, so we can install the APR Stage I tune, and start doing the programming part, of each piece of emissions equipment/lines/hoses, that we can remove to clean up the engine bay as much as possible.
Got underneath the car with a tape and a protractor, and realized there is no way I am exiting the exhaust out of the passenger side like I wanted. So against my better judgment, I am going to follow the stock exhaust path, and cut it short, with a 90 degree exit just in front of the drivers side rear wheel. There are just too many fuel lines on the passenger side, that the exhaust pipe would be directly under.



Edited 1 time(s). Last edit at 12/29/2016 03:13PM by DanielSL.
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Attachments:
open | download - Tunnel forward.JPG (52.2 KB)
Tunnel forward.JPG
open | download - Tunnel rear.JPG (45 KB)
Tunnel rear.JPG
DanielSL
Daniel
Godlike Moderator
Location: Vero Beach, Florida
Join Date: 03/02/2016
Age: Midlife Crisis
Posts: 304

Rally Car:
2005 VW Mk. 4 Golf GTI 1.8T


Re: Mark 4 VW 1.8T GTi Build - RallyCross - MF Class
December 29, 2016 03:22PM
After playing with weights, and tire sizes, we finished setting the ride height. Took out the Jetta VR6 springs, and installed Golf R32 springs at the suggestion of the shop owner. Between the VR6 and the AWD components of the R32, the springs are designed to handle 50-60 lbs more load than the standard Jetta VR6 springs.
Settings are now at 28 1/4" to bottom of fender lip front, and 27 1/4" to the bottom of the fender lip rear. Once the front end is re-assembled, we are looking at adding 60-75 pounds directly to the nose of the car, so it should be darned close to perfectly even once everything settles in.
Once the spring choice was finalized; I took off the 205 DMacks, and set the car to all 16/65/15 Michelins, as these are the smaller tires. As the suggestion by all was to run narrow tires on this car, I am going to run the Michelins all season, and use the DMacks just as alternates. Once the Michelins are worn too far to use, I will switch out to the brand new 185 DMacks. Might as well use up the older, used tires while learning how to drive this thing.



Edited 1 time(s). Last edit at 12/29/2016 03:26PM by DanielSL.
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Attachments:
open | download - Ride Height DS.JPG (37.4 KB)
Ride Height DS.JPG
open | download - Ride Height PS.JPG (40.1 KB)
Ride Height PS.JPG
open | download - Ride Height 01.JPG (47.2 KB)
Ride Height 01.JPG
open | download - Ride Height 02.JPG (48.3 KB)
Ride Height 02.JPG
open | download - Spare just fits.JPG (46.8 KB)
Spare just fits.JPG
DanielSL
Daniel
Godlike Moderator
Location: Vero Beach, Florida
Join Date: 03/02/2016
Age: Midlife Crisis
Posts: 304

Rally Car:
2005 VW Mk. 4 Golf GTI 1.8T


Re: Mark 4 VW 1.8T GTi Build - RallyCross - MF Class
December 29, 2016 03:35PM
I wanted to post some photos of the lower control arm differences, which made me choose to swap over the entire Audi lower sub-frame. The first photo is the stamped steel LCA's on the Mk. 4 VW's.
The following photos are of the cast units from the Audi TT.
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Attachments:
open | download - Stock VW - LCA.JPG (51.8 KB)
Stock VW - LCA.JPG
open | download - Audi DS - LCA.JPG (47.6 KB)
Audi DS - LCA.JPG
open | download - Audi PS - LCA.JPG (48.3 KB)
Audi PS - LCA.JPG
GravelSpeed
Clint Fast
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Location: Fletcher, VT
Join Date: 02/09/2015
Age: Midlife Crisis
Posts: 12

Rally Car:
Subaru WRX STI / Ford Fiesta R2


Re: Mark 4 VW 1.8T GTi Build - RallyCross - MF Class
December 29, 2016 03:48PM
Hi Daniel,
Interesting build you have going here.

Maybe you know already, but just a quick mention that the left rear tire is mounted backwards. This will probably make no difference for you but just so you know.

Pic
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DanielSL
Daniel
Godlike Moderator
Location: Vero Beach, Florida
Join Date: 03/02/2016
Age: Midlife Crisis
Posts: 304

Rally Car:
2005 VW Mk. 4 Golf GTI 1.8T


Re: Mark 4 VW 1.8T GTi Build - RallyCross - MF Class
December 29, 2016 03:51PM
Thanks, Clint. Bad, sponsor, bad! I didn't even notice that. I picked up 13 wheels/tires in one batch from the shop. I am going to have to check every one of them now, as the kid doing the mounting must not have paid very good attention. Aarrgghh!!!!

Edit:

Looking at the first photo on this page, when I had the directional spares mounted, at least it looks like those two are mounted correctly.



Edited 1 time(s). Last edit at 12/29/2016 03:55PM by DanielSL.
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GravelSpeed
Clint Fast
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Location: Fletcher, VT
Join Date: 02/09/2015
Age: Midlife Crisis
Posts: 12

Rally Car:
Subaru WRX STI / Ford Fiesta R2


Re: Mark 4 VW 1.8T GTi Build - RallyCross - MF Class
December 29, 2016 03:54PM
Quote
DanielSL
Thanks, Clint. Bad, sponsor, bad! I didn't even notice that. I picked up 13 wheels/tires in one batch from the shop. I am going to have to check every one of them now, as the kid doing the mounting must not have paid very good attention. Aarrgghh!!!!

Hey, at least it's a left tire!
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DanielSL
Daniel
Godlike Moderator
Location: Vero Beach, Florida
Join Date: 03/02/2016
Age: Midlife Crisis
Posts: 304

Rally Car:
2005 VW Mk. 4 Golf GTI 1.8T


Re: Mark 4 VW 1.8T GTi Build - RallyCross - MF Class
December 29, 2016 04:00PM
Yeah! I have 4 ZE80's, and 3 ZE90's. So I put the matched set of ZE80's on the car, and kept the 90's for spares. 1 left, and 2 rights, which made sense to me, as I am more likely to blow a bead or dismount a tire on the passengers side, from what I saw at the RallyCross events last season that I was able to attend.
Everyone always misjudged entry, and blew apart their PS tires. Only one DS, that I remember popping its bead, all season.
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GravelSpeed
Clint Fast
Professional Moderator
Location: Fletcher, VT
Join Date: 02/09/2015
Age: Midlife Crisis
Posts: 12

Rally Car:
Subaru WRX STI / Ford Fiesta R2


Re: Mark 4 VW 1.8T GTi Build - RallyCross - MF Class
December 29, 2016 04:35PM
The 80's should last you quite a while.

You can determine this for yourself in testing, but I don't think you'll find any difference between lefts and rights if you get in a jam for tires. Especially on the rear. It's more about the construction of the carcass and the tread block for your application than the direction the tread block may or may not be pointing. So don't be afraid to mix them up around the car if you need to.
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Pete
Pete Remner
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Re: Mark 4 VW 1.8T GTi Build - RallyCross - MF Class
December 29, 2016 09:24PM
I never noticed a real difference running lefts on rights. I was advised early on that running them inside-out, however, is a really bad idea unless you are a fan of rapid wear. So the directionality is nowhere near as important as the asymmetry.



Pete Remner
Cleveland, Ohio

1984 RX-7 (rallycross thing)
1978
Silence is golden, but duct tape is silver.
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DanielSL
Daniel
Godlike Moderator
Location: Vero Beach, Florida
Join Date: 03/02/2016
Age: Midlife Crisis
Posts: 304

Rally Car:
2005 VW Mk. 4 Golf GTI 1.8T


Re: Mark 4 VW 1.8T GTi Build - RallyCross - MF Class
December 30, 2016 02:33PM
Thanks for the good information, guys.

Anyone have basic alignment ideas for front wheel drive in a RallyCross specification?

On the front, I was thinking 0.25 total toe-in, and as much negative camber as I can get, to start out with. Probably 1-2 degrees positive caster. Rear axle set at 0 toe, and about -1 degree camber, if I can get it out of the stock adjustments.
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