Chris' (worzel) Black LCR - BT Build

[worzel]

Big Update time

Haven't posted for while as not much to report but have been following other members readers rides with great interest and for inspiration.

Just recently paid the balance on some big brakes. Went for K-Sport 8 Pots on 356mm discs with a new set of DS2500 pads & should be with me before Christmas. They are cheap by comparison to most with the same spec and have read mixed reviews but not damning enough to not give them a try. This upgrade will be important for the increase power gains I'm hoping to achieve by going BT.

Today I finally started the BT conversion with the help of Richard the mechanic.

First port of call get the engine & gear box out. This took most of the day, we didn't rush & found it fairly straightforward...with exception to the down pipe, that tested our patience but we got it off. Couple of shite pics

Dropping the engine

Engine out, looks surprisingly clean

Tomorrow we separate engine from gearbox. Richard will get to work on fitting the quaife diff & the Awesome Gti clutch. The old diff is riveted to the crown wheel so will need to drill these out I think. The new diff will be bolted on with 12 new ARP crown wheel bolts. I will get to work with changing the con rods, exhaust mani, new Bosch 550cc injectors, BT, Down pipe decat and quite a few other bits & pieces...then put it all back together again, simple!?

I've taken off the rest of the week to get this finished and can't wait to get stuck in tomorrow.

More to come...

 

[t0m]

This is an awesome motor mate. Great project indeed

I've loved how you've gone about it mod after mod and just kept pushing on.

This latest update is certainly a biggie! Like you, having the clutch and LSD done is almost a must have now when you think of where the cars have got to. Awesome stuff, really looking forward to seeing this all come together. Why hasn't this thread got more replies? It's a brilliant car.

The rear ARB is a big big mod I found also! Complimented with the front one and front and rear strut braces, you get one very tight cornering LCR which stays pretty flat at speed!

Which 2.0 TFSI coilpacks did you go for mate? I've always wanted some... lol

 

[Ronin225]

Looking good, shame about the time of year to have to work in though, cold fingers
Are you fitting a new cooler too being as its been removed?

 

[James23Parkin]

Awesome update Chris. I hope the next few days go to plan. Keep us updated buddy

 

[ReDBull]

Coming along nicely. How are you finding the Forester?

 

[worzel]

This is an awesome motor mate. Great project indeed

I've loved how you've gone about it mod after mod and just kept pushing on.

This latest update is certainly a biggie! Like you, having the clutch and LSD done is almost a must have now when you think of where the cars have got to. Awesome stuff, really looking forward to seeing this all come together. Why hasn't this thread got more replies? It's a brilliant car.

The rear ARB is a big big mod I found also! Complimented with the front one and front and rear strut braces, you get one very tight cornering LCR which stays pretty flat at speed!

Which 2.0 TFSI coilpacks did you go for mate? I've always wanted some... lol

Thanks Tom. The coil packs were VAG ones but can't remember where I got them from. I got the spacers from IE.

Looking good, shame about the time of year to have to work in though, cold fingers
Are you fitting a new cooler too being as its been removed?

I thought about this, and to be honest I was at the stage of where do I stop. I'm not doing an engine rebuild, just rods. You know what its like it'll probably come back and bite me in the ass. And yes it was f'ing cold.

Awesome update Chris. I hope the next few days go to plan. Keep us updated buddy

Thanks James

Coming along nicely. How are you finding the Forester?

Thanks, I do like the Forrester. Have been chucking it about a bit and seems to love it. I do need to give it a good service though.

 

[worzel]

So from Wed through to Sunday I have been working solidly on the conversion. I've fitted a bigger front ARB to compliment the back one. Think its 25mm and was quite surprised how comparatively small the OEM one is. Looking foward to feeling the benefits of this.

I wished I had taken more pics but time is money and i've got a daily rate with the garage and working on it was non stop.

Cam cover off

Turbo and Mani off

Old and new stuff all over the floor

Head off

Head / valves

New Garrett and JBS Mani fitted

New Awesome GTI Clutch going on

Some bodging to get the new downpipe to fit. This pic is with the engine back in but when we put the new turbo to downpipe bolts on the flange would not clear the top bolt past the Mani...doh!! note to self; check this before putting engine back in

In between pics we installed the LSD. This process was an absolute bitch as we had to drill out 12 large rivets to get the crown wheel ready to take the new Diff. Each bolt seem to take forever to get out and I kept smashing my knuckles with the hammer when trying to hammer them out. We then had to re-assemble the gear box, again neither of us were looking forward to this as getting all the cogs to line up was not easy but after several attempts we got it in about 20mins.

So all back together (ish). Couple of things we are waiting for. 1) new gear bearing seals as can't put the drive shafts back on without these; 2) new 70mm - 50mm reducer 90 degree elbow silicone pipe for the turbo to chargepipe. Then fill it up with oils and coolant, shove revo3 on it and see what happens...

I'll need to run things in for a bit, which in its self is a nightmare as you try doing circa 500 miles on a tiny island, it'll take months so I'll be going out every night I think. In the meantime my brakes should be down soon so will post some more once they are here.

 

[James23Parkin]

Not envious at all

Great update. And all your own work! Wow!

 

[.nOKeCUPRA4TDI]

nice update

 

[t0m]

One word.... EPIC!

That is brilliant work mate, great update to catchup on. So many upgrades going on at once, you must be VERY excited. I was like this yesterday picking my car up after the clutch/diff were installed to mine.

I love the above line 'shove Revo 3 on it and see what happens!' - quality . Really looking forward to seeing how this unfolds mate.

Well done again with the work done.

 

[worzel]

Finally the missus has got the message

Update...currently running the car with no map, a blowing exhaust as the middle pipe isn't properly mated to the back pipe. This was caused by the new turbo and mani sitting slightly higher off the block than the original OEM position so all subsequent pipes are out of align. Just pootling about at the moment when I have time to clock the miles on the new rods / bearings (2 weeks and I've only done 80 miles ). Revo stage 3 will hopefully be installed in the first week of Jan once i've sorted the exhaust.

Have the big brakes, look stunnning and will post pics when I can.

I've put the 19" Oz on my subaru (just to see how they look) and put original wheels back on the LCR. and i'm seriously thinking about purchasing some XXR 527 in Chrome Black. I've checked with supplier to ensure can accomodate the new larger discs. Fell in love with these when posted on this site earlier.

 

[worzel]

Pic of the big brakes; 8 pot callipers and 356 discs from k-sport with new DS2500 pads all supplied by apex performance who gave excellent service. At first glance the quality looks really good.

Pic with a phone to get an idea of scale...they are huuuuge!

To compliment the set up I have ordered motul RBF 600 brake/clutch fluid from opie oils

My OZ alloys are currently on the Subaru & I like the way they look & feel. Quick pic (car is filthy)

Pic of dirty LCR with OEM wheels back on...took this as haven't taken any pics of her like this for ages

So i know the new brakes won't fit under the LCR rims but will easily fit under the OZ..mmm what to do This is why I'm considering another new set of wheels, but this would be the 3rd set I've had since owning the car.

Anyway, my next job is to sort the exhaust & I have two options; 1) insert a 15-20mm spacer where the turbo mates to the exhaust mani, or 2) get the down pipe custom built/moddified. The spacer would easily be the cheaper of the 2 options.

Richard (mechanic) is back on 3rd so will see what he thinks & we'll get the software on, as getting major chatter from turbo at the moment as revo 2 clearly doesn't know what to do with all the new mods.

 

[EL]

Sexy breaks. Xxr 527's would look ace on these Leon's, was thinking about getting a set at one point.

Brilliant t shirt, you must have worked hard for that

 

[James23Parkin]

They do look huge!! What options would you consider with regards to new wheels Chris? It's hard to find a nice looking wheel for the LCR IMO. The OZs are probably one of the most suiting wheels that I have seen

 

[CharlieRCupes]

Amazing work mate. The OZ wheels in 19s suite the Leon so much, looks perfect to me. Even though I'm sure the XXR's will look just as good. Can't wait until this is finished and you've stuck Revo Stage 3 on there lol

 

[worzel]

Sexy breaks. Xxr 527's would look ace on these Leon's, was thinking about getting a set at one point.

Brilliant t shirt, you must have worked hard for that

Ha! You don't know the half of it. I think the concave will look a bit different. Shame they're multi lug but think in a dark colour like chrome black they would be less noticeable.

They do look huge!! What options would you consider with regards to new wheels Chris? It's hard to find a nice looking wheel for the LCR IMO. The OZs are probably one of the most suiting wheels that I have seen

There were several I thought would suit the car; pro race 1.3, but they don't seem to do them in 19 5x100 hub fitment any more but i've always been drawn to Ronal r54's and they do them in 19. Performance alloys do them but say they won't clear the brembos, but I think they just need a spacer. Pic

Amazing work mate. The OZ wheels in 19s suite the Leon so much, looks perfect to me. Even though I'm sure the XXR's will look just as good. Can't wait until this is finished and you've stuck Revo Stage 3 on there lol

Thanks, it's taken some time but I'm pleased how things are now progressing. The XXR's are nice looking for sure but they are 8.75 wide and not sure how they will sit in the front arch, it is only .75 wider than the OZ so at a punt it should be ok

 

[ReDBull]

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Just ignore them they'll go away.

 

[worzel]

Wtf!!

 

[ReDBull]

I've reported them they doing it in a few RR threads!

 

[worzel]

I've reported them they doing it in a few RR threads!

Ok thanks mate.