Thai's grey mk1 Cupra R

[Thai-wronghorse]

Looks similar to the issues I had with my tip install - https://forums.seatcupra.net/index.php?threads/badger-5-tip-fitting-questions.458492/#post-4912893

I found that when I disconnected the turbo pipe to DV pipe suddenly the TIP fitted nicely for the heat shield and filter. And that made it awkward to connect the DV back up. The CM turbo to DV hose is definitely shorter than the OEM one. unnecessary headaches!! I feel your pain.

Ah so you did, extremely frustrating isn't it especially when these TIPS are regarded as one of the best ones available for these engines.
I see your DV pipe was restricting your TIP, the thing is with mine I'd already cut it down to length when I fitted the CM charge pipe and if anything it's still too long as the angle of the TIP isn't right.
The TIP simply needs to be longer imo and allow the ability to trim if necessary.
After speaking to Bill at Badger5 he reckons to bend then heat shield outwards to suit but it's not possible with my particular one as it has a welded base in it.
I've now ordered a Badger 5 heatshield which should complement the TIP better plus the they come with a larger MAF opening and notch for a strut brace so saves me hacking this current one to pieces.
The only hitch is that it's mill finish so I'll need to grab a can of satin black paint before it arrives.

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[Thai-wronghorse]

No additional works to report but I've just taken a few deliveries in today...

4mm silicone vacuum hose x 2m
5mm silicone vacuum hose x 1m
19mm Mocal oil hose x 1m
19mm t-piece fitting
Cloud 9 19mm alloy breather elbow
9mm clear PVC hose x1/2m (for catch tank level)
Badger 5 stainless heatshield
Fluidampr engine damper pulley (used)

Fingers crossed I receive the myriad of hose clamps I've ordered this afternoon or tomorrow so i can start throwing the pipes on.

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[Gokiwi64]

Nice goodies
Is the catch can 300ml or 500 ?

 

[Thai-wronghorse]

I'm not sure actually, it's a saikou michi oil catch can that acquired from the red donor car and then refurbished although I'm not 100% sure where to locate it yet?

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[Gokiwi64]

I found that the 300ml one needed emptying quite frequently but then that could be the state of my engine , also the screw thread can get quite stiff to undo.
I mounted mine initially in the firewall - it looked ugly, then between the battery and slam panel, now its back on the firewall

 

[Thai-wronghorse]

Several productive hours were spent on the car today which was good.

First of all after much thinking and playing around with locations I decided not to run the Saiko Michi oil catch can I had, it was simply too big to put anywhere I was happy with so that was rapidly sold on.

Another much cheaper replacement arrived this morning and for the money I'm really pleased with its quality and will be considerably easier to install up against the bulkhead.

I finally got around to fitting the Audi S3 8L strut brace I've had knocking around for over a year and used on 2 other Leon's previously.
As per usual it was installed used rivnuts which makes future removal for maintenance access a far simpler task.
It could do with a fresh coat of paint but I'll address at a later date, at least all the drilling is done and now this attached it means I hang my oil catch can from it using P-clips.

The new Badger5 heatshield was offered up and allows a bit more flexibility but also needs painting.

I've got a custom MAF housing on it's way, fingers crossed I'll arrive tomorrow.
This will resolve my TIP connection issues without an abundance of couplers and joins.

Exhaust system was bolted up, as with most other things I've transferred it wasn't plain sailing ffs!

The central chassis floor hanger brace had to be forced forwards to fit back on which says to me the while lot is at least 20mm further back then its supposed to be which makes sense as I had downpipe clearance issues as well.
I should be able to sort this properly when I send it to get a sports cat welded in though and I'll get them to reduce the pipe length a touch whilst they're at it to bring the hangers back in line with the factory positions.

Fluids were added!

Engine oil
Gearbox oil swapped
Coolant
PAS fluid

Clocks and ECU refitted

Battery connected and key turned...

It turned over lovely but the friggin immobiliser has kicked in so I need to get my mate to check over the cluster / ECU / key transponder pairing which is rather annoying but it sounded promising.

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[Thai-wronghorse]

Just a brief visit today as I was itching to test fit the the new MAF housing and heatshield.
I also fitted the Fluidampr pulley wheel and a fresh auxiliary belt now the paint had dried.

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[Gokiwi64]

ooh nice shiney metal maf - where did that come from ?

 

[Thai-wronghorse]

https://ebay.co.uk/usr/bbtigwelding

I had this guy fabricate it to my specified length. It's nice quality and the customer service was great.
I plan to add the air straightening grilles from the oem MAF housing to it and still undecided whether to paint it or not.

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[Thai-wronghorse]

Spark plugs gapped properly with my new feeler gauges at 0.85mm, going by what I've read this should be bang on the money with the current engine spec.

Oil catch can and breather hoses fitted.

MAF housing chopped down about 30mm as I'd over compensated and the extra length pushed the air filter too far over in the way of the bonnet strut.
Whilst it was off had a play around with 2 old MAF housings and removed the air straighteners...a bit of filing and they pushed in lovely.
I will take it back off again though to run a bead of hot glue round it as I can't be dealing with them getting dislodged resulting in an obstructed air intake.
A piece of cold air intake ducting was dug out and wedged in place - jobs a goodun!

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[Thai-wronghorse]

Oh and in other news I pulled out a spare manky old rear beam ready for rebuilding and assembled my trolley jack which is rather tasty.

 

[Gokiwi64]

That's a bit posh that jack

 

[Scotty_b]

Mate was the pulley a lightened version or just a different brand?

Also I’d recommend instant metal (the putty you mix) to create the bead on the metal maf rather than glue gun as it will last longer.


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[Thai-wronghorse]

That's a bit posh that jack

It's a 2T Halfords Advanced low profile jack.
I blew the seals in my SGS low profile jack a while ago and had been using my ancient back up piece of crop so was well overdue an upgrade.
I managed to get it a decent price and I'm really impressed with it so far.
It's huge but mega low and goes flipping high real quick, the foot jack and rotating handle are particularly nice touches when working in tight spaces.

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[Thai-wronghorse]

Mate was the pulley a lightened version or just a different brand?

Also I’d recommend instant metal (the putty you mix) to create the bead on the metal maf rather than glue gun as it will last longer.


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No, the Fluidampr pulley wheel is in fact slightly heavier and proven to be vast improvement over the standard rubber stock part, especially on modified engines.

It's strongly advised not to run lightened non damping pulley wheels on these engines as you massively increase the likelihood of harmonic resonance destroying it.

As for the MAF housing air straighteners, they are a decent fit already so a drop of glue will be more than sufficient for piece of mind and easily removed if I ever need to.

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[Scotty_b]

No, the Fluidampr pulley wheel is in fact slightly heavier and proven to be vast improvement over the standard rubber stock part, especially on modified engines.

It's strongly advised not to run lightened non damping pulley wheels on these engines as you massively increase the likelihood of harmonic resonance destroying it.

As for the MAF housing air straighteners, they are a decent fit already so a drop of glue will be more than sufficient for piece of mind and easily removed if I ever need to.

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Ah fair enough, need to look into one then.

Sorry I thought you meant in the outside to stop the pipe coming off!


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[Scotty_b]

Oh and in other news I pulled out a spare manky old rear beam ready for rebuilding and assembled my trolley jack which is rather tasty.

How you getting on with the rear beam rebuild? I will need to do mine over the winter (and front subframe etc.) so looking for any tips or parts to prep as I’m going to fit the ECS wheel centralisation kit as well.


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[Thai-wronghorse]

I've barely touched it tbh, it's fully dismantled but I'm back at work now so it'll need to wait for a bit.
Ideally it needs media blasting and powder coating but not sure how feasible that is at moment?

I've been collecting a few parts up though and so far have the following:

Full length braided brake lines
Creation Motorsport carrier adapters
M-Tec VW mk4 TDI 110 280mm front discs
new genuine brake disc shields
Neuspeed rear anti roll bar kit (taken from an old donor)

I still need sort out rear wheel bearings, ABS sensors, rear beam bushes and a few bolts but my local TPS man isn't allowed to bring any parts home yet so I'll need to wait a week or two for those I reckon.


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[Scotty_b]

I've barely touched it tbh, it's fully dismantled but I'm back at work now so it'll need to wait for a bit.
Ideally it needs media blasting and powder coating but not sure how feasible that is at moment?

I've been collecting a few parts up though and so far have the following:

Full length braided brake lines
Creation Motorsport carrier adapters
M-Tec VW mk4 TDI 110 280mm front discs
new genuine brake disc shields
Neuspeed rear anti roll bar kit (taken from an old donor)

I still need sort out rear wheel bearings, ABS sensors, rear beam bushes and a few bolts but my local TPS man isn't allowed to bring any parts home yet so I'll need to wait a week or two for those I reckon.


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A pain when it slows down but I guess your in no rush.

Do you plan to do similar to the front?

Think mine will be a refresh of what’s there plus some poly bushes and possible rear disc upgrade (want 2 piece front and rear - for looks).

Media blasters I have one near me who is supposedly open but not found a recommended powder coated yet.


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[Thai-wronghorse]

I did the front end not long after I got the car, you can see my progress and parts near the beginning of the thread.

My rear brake upgrade is mostly aesthetic tbh, I just felt the 256mm rear discs looked a little lost in the open spoked 18" R wheels.
It hasn't really cost me much either as I've already sold the existing bits and pieces I had.

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