Stunning work, it is like watching a real restoration.

Mark

Thanks to much mates! I Really love vw 80'and 90'




Before continuing with engine, i made with insulating tape the inside mudguard. If was a oem ride eight i could use a 0.25 mm styrene sheet. But if I used it, my chassis would be raised....and this is not good.

I fitted the selfmade hoses for heater core.

Remembering the Delta HF WRC water canister, I decided to reproduce it also in my GTI.
I started my work using a AA dummy batteries.
After some work, I obtained the wanted shape. I holed the tank for future connection and future bracket on engine struct.

Finally i coated it with bare metal foil and i added hoses using a tube with same color of G12 liquid.

I repainted the fan with gray haze, and i add some detail to radiator fairing (some alu tape on top face of radiator, some alu tape on fan motor and connection for hose to canister and temp sensor)

I also fitted the selfmade clutch cable.

To maintain a little bit clean engine bay, I decided to build a partially hidden engine wiring (all the invisible wiring run inside the chassis)

Ahahahah, thanks Mark....the final part of yesterday job.

Yesterday i quite finished engine coolant system. Just only the final hose from canister to radiator.

I also create another partially hidden engine wiring (it runs nearly the struct and hides inside the left chassis spar)
I cabled the rear light switch, the speedo cable and the oli temp sendor for gearbox and differential (this last is my add and not present on real GTI)

Then i worked for fitting the hose from canister to radiator: With insulating tape i selfmade grommet to fix hose on side left structs. This hose will be partially hidden from extra oil cooler and battery (battery will be lifted to permit the run of other wiring)

Finally i made new bracket for extra oil cooler (i used the present hole inside the engine bay)

Beautifully done throughout and a real pleasure to see.... .. Very well done...

Regards

Alan

Fantastic work, real pleasure seeing this all come together. Great to see the out the box v yours.

Mark

Really thanks for yours words mates! I’m very pleased that you’re enjoying watching and following my build.

I carbon decal the CDA filter airbox and the oil cooler fairing. Also i add the oil filter decal. Other engine decals will come later

Finished the engine, my attention swing to one of my preferite parts of car: the exhaust system

Like on my real gti i deleted central an middle silincer to obtain a direct flow exhaust

I also deleted the oem twin tailpipes and added a big bore tailpipe like sport inox exhaust N group (like Bastuck sport auspuff)

I used the chassis as template to finf correct shape of my new exhaust system

I coated it with a first primer coat to check anything to rework. Then putty and a new paper sanding. Then i reprimered, i coated with white aluminium paint and a final smoke TS71 coat (specially in the first section of the system)

While I'm waiting the drying of exhaust paint, i redid all the brake lines fitted on underbody. I fitted the chassis grommet and i uses 1 mm metal wire for new brake lines. I self made new hydraulic joint for brake lines and i jointed them on new rear braking distributor.


I also added new selfmade alu clamps with bolts on exhaust, i added some weld lines.
I finished the work on manifold with thermal banding.
To reach the right color i painted it with a first coat of titanium gold and finally a smoke coat

Suddendly i used the tamiya powdwers to light the exhaust point (blu and red burn effect). I also lighted the tailpipe to simulate the heating due backfires.

I also wheatered the chassis heatshield and finally i fitted my full illegal exhaust system..

I full repainted in matt black (2 final clear coat matt) the subframe, arms, rear axle and front engine bar

I detailed some bolts and added fixing nuts for the arms

In the past months i mistakenly painted in gun metal the bracket for rear axle. In the real gti this piece is part of the chassis....so i repainted in new blu color like frame.

I started the work on brake system. The caliper and disc out of box are quite hugly.

The caliper kit are in 2 pieces, i want it monobloc like the real
The disc are correct but without personality for my project

I dediced to use the rc disc that are metal and drilled. Another postive point id that the disc is also centre hub for rim, but i need to work because rc disc is quite larger then oem kit

So i made the same work on real big brake conversion: i remade the caliper bracket using a m6 large washer.
I “welded” with cianoacrylate and bicarbonate the caliper to washer. Ase template to have right fitting i use a 6mm drill and i clamped washer to disc...than i made some “welding point”. Finally i finished the welding job.

Imho the disc brake is more good looking

Next step: putty, sanding and final painting.