iTB Ibiza Cupra 16v Track Toy - Engine Rebuild, Aero & More Page 73+

[Dave_R]

As I mentioned I got hold of a Peloquin Diff, so off came the gearbox and it went up Newport Gearbox Centre to get the LSD fitted to its new home inside my gearbox!

This is what the box looked like when I took it off

And after Auto Glym Engine Cleaner and a jet wash

When I had it back there was a problem with the flanges (love that word). The thing is with a 02A box the flanges should be push in and held in by a circlip but the standard diff had threaded holes on it to bolt the flanges to it.

The Peloquin didn’t so the flanges could easily be pulled out, emailed Peloquin in the US of A and he rung me at 2am (our time) after I finished work at 10pm that night and was back in work at 6am so as you could guess I was in my own little world talking to him.

He told me that the only difference between the diff for the 02A (16v box) and 02J (20vT box) was that the 02A was push in and the 02J was bolt in but some how my 02A was bolt in. He managed to give me the part number for the push in flange that I needed so I ordered that one and waited a few days!

While I was waiting for the new flanges I painted the box silver and the bolts and “VW” badge black.

Once the flanges came I went to fit them and they wouldn’t fit correctly, there was a thinner lip on the flange that wouldn’t let it fit into the dust seal in the green housing. Spoke to a mate that was going to fit the diff originally but went on holidays when I wanted it did he told me that I had to remove he green housing.

You can see the green lip on the outside

Pulled it off

And fitted a new dust seal from a Mk2 Golf, which I also ordered when I had the flanges just in case.

Fitted a new clutch once the box was off, use to have a Golf VR6 clutch when I had my engine work done but when I took the box off last year for the short final drive the thrust bearing went and I had a spare 16v clutch so refitted them.

But with the 16v clutch when I tried to park outside the missus house and a hill the clutch would smell badly, so decided to fit another VR6 clutch again.

 

[Dave_R]

Went to adjust my FK Highsport Coilovers because the snot was way too low for my liking anymore and it wrecked my front arches being so low. I decided to raise the car but found them to be seized solid (3 years on the car and never touched them after fitting).

Decided to get a custom set up on the car, Koni Adjustable Shocks and Faulkner springs made up but I don’t really know much about suspension set ups. Emailed Faulkner asking for advice and they told me they don’t know what their springs go on, just build to the customers spec. Tell them what diameter spring, length and poundage and he make them, so he gave me contract details of 2 people that could help me.

First one said he would sort me out with something but he was busy so phone but in a week. Rung up a week later told me again he was busy and asked for the car’s details but wasn’t interested in the car being stripped or anything (thought the car being lighter than standard might change something).

Told me he get back in touch but never did, rung him again and told me to just get a full koni set. So I contacted the other company, he said he look into it but is going on holidays for 2 weeks so will sort it when he gets back, waited 2 weeks and all he told me was he’s got Koni adjustable on his Golf R32 with AVO springs and they amazing! Again not what I wanted!!!!

After this I lost any interest in the car and just forgot about it for a month. Finally got the love back from it after weeks and weeks of looking at Evo’s, scobbies, lotus’s and thought I came this far might as well finish it.

Priced around for a Koni Adjustable Kit (Springs and shocks) ordered them from Larkspeed and had to wait for 3 weeks to have them made up from Holland. Once I finally got the kit noticed that because I’m going from coilover back to springs and shocks, I haven’t got any of the top mounts or anything so ordered them from Seat.

Went to fit the kit and noticed I was missing the base plate for the rear springs, got in touch with Koni and waited 2 weeks for them. Once I got the plates I lost the rest of the kit, to this day I haven’t seen them, I’m sure my dogs ate them or something.

Spent weeks and weeks trying to get the parts off Koni and when I finally did, fitted the kit and the car looked standard height!

This is what a 40mm drop should look like

This is what mine looked like:

 

[Dave_R]

Put the snot on another weight loss programme! Removed all the sound deadening, not a job I would like to do again, also fitted a Odyssey PC680 battery, the battery holder will be done in Matt Black done.

 

[Dave_R]

Went to change my brake pads and disc’s and found that one of the dust seals on the brembo’s wasn’t looking too good so had them refurbed and painted by Godspeed Brakes and then painted the rear callipers.

Fitted Ferodo DS2500 pads with grooved 305mm discs and Pagid Fast Road pads and grooved rear discs.

 

[Dave_R]

Trying to sort out the suspension for the car I decided to go for a 60mm drop using spax springs. Removed the front shock and then the Koni spring, assembled it all but together and found that the Spax spring wouldn’t compress, it was just moving around as it wanted to.

I had enough of the standard ride height of the snot and the Spax spring was too short for the Koni shock so I ordered a set of Bilstein B14 Coilovers. Took only a week to come from Germany, I got them Tuesday and by Wednesday morning I was fitting them.

The front went on with no problem but when it came to the rear the thread pin that you place the bushes onto and then the nut to hold it in place was too short.

Here’s a pic showing the difference between the Koni to the Bilstein threaded pin

I had a set of uprated Mk2 Golf rear bushes that were shorter than the standard ones and built up these would allow the pin to become long enough.

With Standard bushes

Rung DPM Performance and he emailed Bilstein to check they the right parts which they were. So I took their word and tried to fit them again, lowered the car down so the full weight was on them and still no luck. Thinking that the car is lighter than standard I decided to jump in the boot and bounce up and down while trying to turn the nut and it went, Happy Days!

The Bilstein next to the Koni’s
Front

Rear

How the car is sitting now

 

[Dave_R]

Don’t know if I have already mentioned, I have a set of Carbon Fibre door cards which I had just before xmas time, will get pics of them up soon.

Now for the most up to date bit………..

The snot was taken to the bodyshop yesterday (Monday). I took it to Old School Engineering in Bleancwm, this is the place that RS Rob had his fez done and pookie’s old Paxo when he sold it.

Before it went up, I was empty the inside of the car and found a pen so got bored and decided to write all over it then left the missus kid and my nephews draw over the panels that were getting replaced.

Then went to Cardiff to hire a trailer for the day and took the car to OSE

The list that I had to make of what I wanted done follows:

• Spray car standard colour outside and inside.
• Spray DTM Mirrors with the bases and the slam panel Matt Black.
• Fit bonnet pins.
• Colour code standard mirrors (caps).
• Fit Spoiler
• Fit new tailgate.
• Flock dashboard.
• De-lock passenger door.
• Rust on rear arches and passenger door.
• Colour code side skirts.
• Make plate up for oil catch tank.
• Spray Battery cover in the boot Matt Black.
• Fit mud flaps on the front.

I will be going up there over the weekend to see how the work is coming along and of course get some more pics up!!

 

[Martin M]

Nice to see it going back together Dave!

 

[Dave_R]

I don't know what to do with myself no more..... past few months have been waiting for it to stop rainning and work on the car, now I have nothing to past the time on the weekends

 

[PhilW]

Im gonna go up the bodyshop and tell them to paint it a proper colour.

 

[suj]

woah, no updates for ages then a good long read! can't wait for it to be done!
how much suspensions did you go through? send me some lol

 

[Dave_R]

Phil it's going the best colour a mk2 can be!!

Well the Koni's are going back when they finally send me their address and the Spax had to be made up for me so they are for sale. Cost me £80 odd, I'm selling them £70 ono I guess.

Be honest I should have gone for the Bilstein's in the first place but I was being gay I think hehe

 

[AlpineWhite]

Good to see some progress Dave! I never had you down as a Natural Copper fan! Still, welcome to the club



PS ride height looks a LOT better!

 

[Dave_R]

Good to see some progress Dave! I never had you down as a Natural Copper fan! Still, welcome to the club



PS ride height looks a LOT better!

Don't you mean brown

I'm much happier with the height but it may alter when I get it all corner weighted..... but can't see the corner weight lowering the car much more.

Will be popping up to the bodyshop on saturday to see how it is going.

Forgot to say to him that I want the front bumper cut by the number plate like on the F2 Rally car like this,

but wont you see the slam panel bit?? Know Roly and Chris have done it so one of you two let me know

 

[crezz]

dave you got your old skirts kicking about still?

 

[Martin M]

Forgot to say to him that I want the front bumper cut by the number plate like on the F2 Rally car like this,

but wont you see the slam panel bit?? Know Roly and Chris have done it so one of you two let me know

Dave,

I'm just cutting mine out to look a bit like this. I think there's about 10-15mm to play with from the top before the crashbar is showing. It's hard to cut and get the lines straight though

 

[CraigW]

Good progress mate. Hadnt up-dated in a while but you've up-dated alot in one go.

I wouldnt mind a kiwi Ibiza, always had a liking for that colour.

Dave can I ask a question, what did you all order with the new side-skirts??

Reason Im asking is that Ive aquired a set, I know I need a couple of jacking point covers but unsure if I need end caps etc. Want to get part numbers etc just incase I need them.

 

[Dave_R]

The end caps are on the side skirts, it's one complete piece.

Crezz I have the side skirts off my car, one's damaged and a set I had off ebay.... end cap is slightly damaged but nothing that would be noticed once fitted. I was being fussy since I had all dealer parts and that.

 

[Dave_R]

Dave,

I'm just cutting mine out to look a bit like this. I think there's about 10-15mm to play with from the top before the crashbar is showing. It's hard to cut and get the lines straight though

Cheers Martin! Think I give him a ring tomorrow and get his email address to send him a pic and see if he can look at it. Cutting it straight is one thing I don't need to worry about

 

[Dave_R]

Well gonna pop up to the bodyshop tomorrow afternoon, I'm nerves to what I'm gonna see
Will be taking a camera with me as well

 

[crezz]

yeah mate, i wanna see the fresh gooey-ness of the new snot paint! looks awesome when its all the same colour and shiney