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 Post subject: Re: 93 turbo gti
PostPosted: Mon Mar 30, 2020 3:31 pm 
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Joined: Thu Apr 28, 2016 12:23 am
Posts: 375
Location: adelaide
Hi mate, have you any updates, I heard your car is moving again


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 Post subject: Re: 93 turbo gti
PostPosted: Mon Mar 30, 2020 5:00 pm 
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Joined: Fri Oct 20, 2006 12:08 pm
Posts: 178
Location: NSW
Hahaha i was actually thinking i needed to update this thread with some progress

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 Post subject: Re: 93 turbo gti
PostPosted: Mon Jun 29, 2020 5:40 pm 
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Location: NSW
Soooo probably long overdue for an update here.

Before that I would just like to say a huge thank you to Dan AKA Zuboo. This man not only sold me some parts to make the gti awesome, but also carted my car around so that it could be worked on by the best in the gti business and housed it for nearly 6 months whilst all this took place. This mans kindness and understanding definitely re instills ones confidence in the human race. I cannot express my gratitude enough to this man.

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 Post subject: Re: 93 turbo gti
PostPosted: Mon Jun 29, 2020 5:56 pm 
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Joined: Fri Oct 20, 2006 12:08 pm
Posts: 178
Location: NSW
So I must say I have always been a bit of a Zuboo and DMW fanboy for a long time so it's no surprise that this is where I looked to start my next stage of modifications. Baring in mind that I wanted a tough and reliable street car that will scare the pants off WRX and HSV owners.

I knew that I needed a new ecu so I spoke to Zuboo who was in the process of starting his Kswap. I managed to secure his old Haltech PS200, coil over plug setup and MSD CDI and associated sensors, crank angle and cam sensor and loom. This took allot of the guess work out for me and would save me time in the long run.

Next I had to address the gti's Achilles heel, the gearbox. After speaking back and forth with Zuboo I figured why not just buy a tried and tested 1.6 franken box with all the fruit. I purchased the box from Zuboo who kindly organised for a custom more streetable clutch to be made.

Next the gearbox went to DMW Daves workshop. I purchased an MFactory LSD which DMW Dave fitted and modified the speedo drive so as to have it compatible with the standard gti cluster. Once the box was apart DMW Dave replaced a worn 3rd gear synchro which was showing signs of wear.


Attachments:
1.6box.jpg
1.6box.jpg [ 173.68 KiB | Viewed 33 times ]

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 Post subject: Re: 93 turbo gti
PostPosted: Mon Jun 29, 2020 5:58 pm 
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Joined: Fri Oct 20, 2006 12:08 pm
Posts: 178
Location: NSW
Gearbox and ecu pics


Attachments:
PS2000.jpg
PS2000.jpg [ 96.42 KiB | Viewed 797 times ]
msd cdi.jpg
msd cdi.jpg [ 74.53 KiB | Viewed 796 times ]
gearbox.png
gearbox.png [ 425.9 KiB | Viewed 795 times ]

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 Post subject: Re: 93 turbo gti
PostPosted: Mon Jun 29, 2020 6:09 pm 
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Joined: Fri Oct 20, 2006 12:08 pm
Posts: 178
Location: NSW
It was about at this stage that I began to smell burning oil under load and being the paranoid person that I am, set out to build a more turbo friendly engine.

I took a spare engine to Illawarra Automotive Specialists who do a host of things including specializing in engine rebuilds.

I wasn't looking to reinvent the wheel with this one, so I kept it to a tried and proven setup. the engine was decked bored and honed to fit a set of vitara pistons. I sourced a set of forged con-rods and new bearings as well as the typical ARP head-studs, Suzuki MLS head-gasket etc. The crank was polished and linished before the bottom end was reassembled. The head was ported and polished with a new set of valves, valve stem seals and freshly cut seats. I used spool valve springs and a set of new lifters to finish off the engine build before reassembly and fitment.

After a run in period the car, still running a chipped turbo ecu, was put on the dyno. The car made a respectable 146hp atw on wastegate pressure which was around 10psi. Having said this, the car was pushed past 6000 rpm due to the AFRs leaning out.

I had a genuine walbro 255 fuel pump installed in preparation for the Haltech fitment.

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 Post subject: Re: 93 turbo gti
PostPosted: Mon Jun 29, 2020 6:13 pm 
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Joined: Fri Oct 20, 2006 12:08 pm
Posts: 178
Location: NSW
Engine pics


Attachments:
old engine bay.PNG
old engine bay.PNG [ 582.21 KiB | Viewed 802 times ]
vitara pistons.jpg
vitara pistons.jpg [ 131.4 KiB | Viewed 30 times ]
rods and pistons.jpg
rods and pistons.jpg [ 121.25 KiB | Viewed 36 times ]
mls head gasket.jpg
mls head gasket.jpg [ 85.28 KiB | Viewed 31 times ]
mls head gasket.jpg
mls head gasket.jpg [ 85.28 KiB | Viewed 31 times ]
Headstuds ARP.png
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garage 2.jpg
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engine1.jpg
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engine arp studs.jpg
engine arp studs.jpg [ 120.74 KiB | Viewed 32 times ]
ARP.PNG
ARP.PNG [ 442.5 KiB | Viewed 798 times ]

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 Post subject: Re: 93 turbo gti
PostPosted: Mon Jun 29, 2020 6:18 pm 
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Joined: Fri Oct 20, 2006 12:08 pm
Posts: 178
Location: NSW
I drove the car around like this for a while secretly disappointed with the current standard of performance. I began to look around at where I could go to have the gearbox and ecu fitted knowing full well that experienced hands were what I required.

So being bored I decided to upgrade the stereo. I had a Alpine single din head unit, alpine type r 6.5 inch splits, 8 inch type R sub and an Alpine 4 channel amp fitted in a custom boot enclosure.


Attachments:
custom install.jpg
custom install.jpg [ 65.14 KiB | Viewed 795 times ]

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 Post subject: Re: 93 turbo gti
PostPosted: Mon Jun 29, 2020 8:00 pm 
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Joined: Fri Oct 20, 2006 12:08 pm
Posts: 178
Location: NSW
So after careful deliberation on where I was going to have the remaining work done I decided to take the family on a holiday to Byron Bay and make a quick trip up to Brisbane to collect the completed gearbox from Zuboo.

I met Zuboo at DMWDaves to collect the box and we got talking, well not so much talking, more of receiving some much needed knowledge from the gurus in gti building. With very little coaxing and a very kind offer from Zuboo the decision was made to courier the car up from NSW to Zuboo's abode until DMWDave was able to fit my car in to install the 1.6 franken box.

It's here I must express my gratitude to DMWDave as his level of experience and professionalism really speaks for itself. He installed the box with some minor modifications to have everything sitting as if it had came from the factory.


Attachments:
1.6box.jpg
1.6box.jpg [ 173.68 KiB | Viewed 34 times ]
zuboo garage2.jpg
zuboo garage2.jpg [ 95.33 KiB | Viewed 791 times ]
zuboo garage.jpg
zuboo garage.jpg [ 79.14 KiB | Viewed 794 times ]

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 Post subject: Re: 93 turbo gti
PostPosted: Mon Jun 29, 2020 8:11 pm 
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Joined: Fri Oct 20, 2006 12:08 pm
Posts: 178
Location: NSW
The next step the car was off to Micks Automotive Wiring Solutions to wire up the Haltech, Coil setup MSD CDI and some suzuki sport defi gauges. Now Mick Rye is another person I must thank, he is much like myself very OCD and did a phenomenal job getting everything sorted fitting the haltech PS2000 in the factory ecu position which god knows must have been a pain in the ass. Mick identified some shitty wiring and subsequently removed a mess of crap and installed a new immobilizer for good measure.


Attachments:
coil on plug.jpg
coil on plug.jpg [ 88.21 KiB | Viewed 793 times ]
piping.jpg
piping.jpg [ 82.38 KiB | Viewed 793 times ]
guages.jpg
guages.jpg [ 64.1 KiB | Viewed 792 times ]

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 Post subject: Re: 93 turbo gti
PostPosted: Mon Jun 29, 2020 8:22 pm 
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Joined: Fri Oct 20, 2006 12:08 pm
Posts: 178
Location: NSW
I know I have been raving about the people who had worked on my car and the next person is no different. Rob from Definition Motorsport is an absolute legend and an all around nice guy who is the very definition of professional (no pun intended).

Rob set out to finish off some wiring with the cam angle sensor and fit up the 60mm sr20 throttle body. To go with the larger throttle body rob made up and re routed the intercooler piping utilising larger diameter alloy piping for its improved heat resistance qualities.

Thanks again to Zuboo who sold me some ID1000 injectors and genuine suzuki power steering improving the on road drive ability which was all installed by Rob.

Whilst Rob was sorting out some odds and ends I had him install a oil cooler to help keep the temps in check during the summer periods whist giving it the beans.


Attachments:
power steering.jpg
power steering.jpg [ 97.1 KiB | Viewed 790 times ]
power steering.jpg
power steering.jpg [ 97.1 KiB | Viewed 791 times ]
hoists.jpg
hoists.jpg [ 92.62 KiB | Viewed 794 times ]

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 Post subject: Re: 93 turbo gti
PostPosted: Mon Jun 29, 2020 8:23 pm 
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Joined: Fri Oct 20, 2006 12:08 pm
Posts: 178
Location: NSW
Power steering


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 Post subject: Re: 93 turbo gti
PostPosted: Mon Jun 29, 2020 8:36 pm 
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Joined: Fri Oct 20, 2006 12:08 pm
Posts: 178
Location: NSW
Finally it was dyno day, a day I had looked forward too for a long time and ........ it made a whopping 158hp atw on 15psi. Something was very wrong. I felt gutted and quite frankly I was shitting myself as my tight budget was almost consumed.

This is where both Rob and Zuboo were worth their weight in gold. Through their wisdom and experience I was told not to worry and the car was in good hands. I must say when your car is 1000kms away and is being worked on by people whom you have never met you sometimes question your life choices. Not on this occasion however, I knew it was in the best possible hands and I was not dissapointed.

Rob identified a faulty blow off valve which was a used evo 8 BOV that had been installed when the Suzitech turbo kit had been installed. I had this installed against what had been recommended by them at the time, I should have listened to Pete from Suzitech and installed a new turbosmart unit. A silly man pays twice.


Attachments:
dyno graph.jpg
dyno graph.jpg [ 82.59 KiB | Viewed 788 times ]
dyno3.PNG
dyno3.PNG [ 1.36 MiB | Viewed 788 times ]
dyno2.jpg
dyno2.jpg [ 106.21 KiB | Viewed 785 times ]
dyno.jpg
dyno.jpg [ 104.24 KiB | Viewed 786 times ]

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 Post subject: Re: 93 turbo gti
PostPosted: Mon Jun 29, 2020 8:47 pm 
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Joined: Fri Oct 20, 2006 12:08 pm
Posts: 178
Location: NSW
Then it was time to finally get the car home and I must say, I could not be happier. Even the after returning Rob and Zuboo have been more than happy to talk to me about everything. This is something that will not be forgotten and again I can not recommend any higher the people whom have worked on my car making it what it is today.

So whats next? Well first I'm looking to fit up a set of Advan Neova AD08R tyres wide a little better which should provide a bit better cold grip and handling in the wet compared to the Federal RSR I currently have on.

After that I will have to address the suspension, its a bit clunky and old. I have ordered a set of Harris Motorsports rear camber plates which I will fit in conjunction with some BC coil overs or Tiens? I'm not so sure yet, perhaps I can get some advice from DMWDave in relation to whats the best option.

After the suspension is rectified I will install a Haltech IC-7 dash to bring the cockpit into the modern era. After that I will address the paint and finally fit all the new window moldings I have had sitting in my wardrobe.

Hopefully you guys have enjoyed the latest build progress and I am open to suggestion/reccomendations.

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 Post subject: Re: 93 turbo gti
PostPosted: Mon Jun 29, 2020 9:37 pm 
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Joined: Sun Jul 17, 2011 2:22 pm
Posts: 551
Location: Adelaide
So good to see the old redline members still helping each other out and keeping these cars alive. Awesome update man, car looks fantastic. Well done!

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94 mk3 gti. Bd14s, extractors, group A chip, adjustable cam gears, 10.2mm leads. 69.6kw atw - Sold
2010 Suzuki swift sport, hks turbo kit.
94 Gti undergoing resto with M16a.


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 Post subject: Re: 93 turbo gti
PostPosted: Mon Jun 29, 2020 9:39 pm 
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Joined: Sun Jul 17, 2011 2:22 pm
Posts: 551
Location: Adelaide
Also got some camber plates and would be interested to know some opinions on what suspension to use as I’m at the same stage of needing some coilovers.

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N/A all the way!

94 mk3 gti. Bd14s, extractors, group A chip, adjustable cam gears, 10.2mm leads. 69.6kw atw - Sold
2010 Suzuki swift sport, hks turbo kit.
94 Gti undergoing resto with M16a.


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 Post subject: Re: 93 turbo gti
PostPosted: Tue Jun 30, 2020 8:45 am 
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Joined: Thu Apr 28, 2016 12:23 am
Posts: 375
Location: adelaide
=D> great result , great to see zubbo had given you his time out from his big build to help out.
i must point out that you are a top bloke as well,
with your help with gathering parts and information and your build has inspired me to go so much further with my build.
your the reason my bank balance is so low. lol


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 Post subject: Re: 93 turbo gti
PostPosted: Tue Jun 30, 2020 5:23 pm 
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Joined: Fri Oct 20, 2006 12:08 pm
Posts: 178
Location: NSW
Thanks guys it was great to have the Redline members look after each other like the good old days.

Gticon hahaha I don’t think mine is up to your standards mate and I am looking forward to seeing your results once its back on the road mate.

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