Bill's G3F Build

[Bill Shaw]

Front suspension & brakes are done. Audi TT spindles, ball joints, A-arms, and calipers, Hawk HPS pads, Jetta tie rods & brake hoses, all new OEM bolts, nuts and bushings.

I need to get this thing moving, my brand new rotors are starting to show rust!

[Bill Shaw]

Today's lesson learned - the rear sway bar has to go on before the rear K member, there's just no room for it to go in after. Side room may be an issue too. I need to pull the springs off and check the full range of travel.

Anybody else planning on front & rear sway bars?

[Bill Shaw]

The fuel cell is in.

[John Phillips]

Sweet! Glad to see forward progress...and signs of life on this board! Parts are on the way, I think, so maybe more action here soon!

[Bill Shaw]

Got brakes bled tonight. It doesn't run but it can stop! Even more important, I can torque the axle nuts now.

[Bill Shaw]

I moved the GF out of the garage yesterday so I could use the lift for another car, and I shot a 360 sequence around it while I was at it. Check it out...

360 degrees around Bill's GF

[Bill Shaw]

Cleaned the garage and started assembling the engine this week. So far everything looks good.

[Olli]

Guys,

I couldn't help but notice the fuel cell. What are the dimensions ? I might have that exact cell sitting here at home. It is brand new. I don't know if Mark includes it or not but I would sell it pretty cheap.

Olli

[Bill Shaw]

Fuel cell is included, Olli.

I worked a bit more on the engine assembly today.





Found the upper chain lower sprocket is chewed up, and can't find my spares. I need to find a replacement.

[4229GL]

is the color anything special on the block? significance or something? It looks nice.

[dukegrad98]

Originally Posted by 4229GL

is the color anything special on the block? significance or something? It looks nice.

It's a Ford block!

Cheers, John

[Bill Shaw]

The color is indicative of the fact that I am sick of black - so far everything on the car is black, very little detail shows in the pics because it is all black.

(I also had 1/2 pint of POR15 engine paint left over from the Coupe build, so you're close, John! :-) )

[Bill Shaw]

I found my missing sprocket! Just in time, I was about to go buy one. It was in the little red compartment box under the grey roll-around bench. I must have 2 hours into looking for it, does that count as 'build time'? :-)

[Bill Shaw]

I almost have an engine again!

[Bill Shaw]

Just sayin...

[Bill Shaw]

I'm on hold with the engine waiting for a rear main seal, so I started working on electrical. Here's what I've come up with so far...



Here's where I decided to mount the power distribution box. It needs 2 wires extended to the plug on the distrib box, and a large gauge wire to the alternator/starter.

Note I've also decided to mount the charcoal canister up here. It's near the tank (where VW intended it), and I need the space Michael chose to mount my coolers. It mounts to the bottom and top horizontal fuel cell braces, I need to build the top bracket for it still.



Here's the driver's side of the front end wiring harness. I stripped the harness wrap to move the distribution box, yuk what a gooey mess! PB Blaster does a good job of removing the goo. I circled 2 connectors that need to be extended, one to the dist box, and the other to the engine harness out back. Did you guys need to extend this one to the engine harnesss, too?

It will all be wrapped up again in harness wrap and mounted properly before I'm done, of course.

[Bill Shaw]

Been down for 5 days because the filter on the telephone pole died. No internet gave me time to update, so major updates are in the engine and gocart sections of my GF pages.

[Bill Shaw]

In keeping with the recycling theme, the upper evap canister bracket was recycled from one of the dash brackets. It'll get cut along the line.

[John Phillips]

Sweet, I was trying to think of a way to use those dash brackets!

[RedJoker]

Just out of curiousity, how are you running your coolant lines? Most everyone is sending them right through where you are mounting the canister. I'm not saying your wrong because I want to see alternatives.

[Bill Shaw]

I didn't get that far yet.

[Bill Shaw]

The new radiator is in and the fuel lines are run to the rear.

The coolant lines are going to the drivers' side down and around the fuel cell to the tunnel. I bought another upper radiator flange to use on the bottom to point it straight back instead of angling over.

[John Phillips]

Sanitary fuel lines! Can't wait to see how the coolant lines run.

[Bill Shaw]

[D2W]

Bill I can't remember what you are using for the turbo kit. Ebay cheap stuff like Mark has planned or the domestic good stuff?

[Bill Shaw]

Actually, you can sort of see it in the pic above in the bottom right corner - PTE - Precision Turbo Engineering (5857SP).

Ceramic ball bearings, billet turbine (above), surge suppressing housing.

I am amazed at the milling in that turbine.

[Bill Shaw]

The fuel pump mounts almost where the original was, so the fuel pump is already wired, just need to crimp some terminals.



I know, the -8 hose is way overkill, but I had some -8 connectors. It's dropping down to -6 from here to the rail.

[D2W]

Bill your build is just incredible, way to go all out. Are you planning any body mods to spice it up? I found the final design to be kinda bland.

[Bill Shaw]

Yes

[Bill Shaw]

If I have it right, on the the block the oil comes out of the center hole and returns to the outer ring, is that correct?




Need to figure out which is in and which is out