Grahams81-Leon 4wd, Big Turbo - Back in the saddle :-)

[Danny@INA]

Here's some pics of mine

I done mine in about 3 days the hard bit was getting the floor back in the car in one some BIG bars needed lol

Here's a link for my build but most of it Is about the engine

http://www.seatcupra.net/forums/showthread.php?t=236121

 

[Ronin225]

Cheers for the pics danny doesnt actually look too difficult
If you could send me the parts list you made graham it would be much appreciated

 

[grahams81]

Cheers for the pics danny doesnt actually look too difficult
If you could send me the parts list you made graham it would be much appreciated

Here you go matey, prices were from Tristan @ Bristol Street Seat Dealer.

Floor Above Petrol Tank 1J6813111C £214.97
Boot Floor 1J6813114A £133.03
Left Inner Wheel Arch 1M6803421A £229.96
Right Inner Wheel Arch 1M6803422A £229.96
Mounting For Subframe Left 1J6801771 £16.55
Mounting For Subframe Right 1J6801772 £16.55
Mounting for Trailing Arm Left 1J6803491E £112.96
Mounting for Trailing Arm Right 1J6803492E £112.96
Cross Member 1J0803531C £122.21
Rear Frame Rail Left 1J0803501C £296.40
Rear Frame Rail Right 1J0803502C £296.40
Mounting For Shocker ? Left 1J6803215A £13.93
Mounting For Shocker ? Right 1J6803216A £13.93
Front frame Rail Panel Left 1J0813119A £47.76
Front frame Rail Panel Right 1J0813120A £47.76
Total £1,905.33

They might be other little brackets etc needed but it's not too easy to see on VAGCAT.

I don't suppose you have any pictures of the downpipe to clear the propshaft / transfer box do you ??, im just trying to picture it at the moment so i can see whether i am going to be able to fit a twin scroll setup with twin external wastegates or whether a Borg warner with a internal wastegate is going to be required...decisions decisions.

Oh and cheers for the link & pictures Danny, i maybe in touch later if i run into bother.

 

[Danny@INA]

 

[Ronin225]

Not the best photo but you can see the added in bend in the upper part of the downpipe which was to clear front transfer box

 

[grahams81]

Cheers for the photo's lads, that will come in usefull when i make my manifold and exhaust up.
Had a read of your thread Danny, one word awesome !

 

[grahams81]

Sorry about the slow down in progress in the thread, i've been away with work for three weeks
Well i got back from Ireland on Monday night, couldn't wait to get cracking again on the car on Tuesday, but it pissed down all day so i ended up cleaning up the garage after the hectic engine rebuild.

So anyways today was a bit better so i managed to get cracking and finished off stripping the S3 shell, it was a pain in the arse to get the frame rails seperated but managed.

Here's a shot with one of the sides off -

Got all the sides off the removed the rear panel, so now just gotta clean all the seam sealer off all the joints and strip the mating faces to bare metal in preperation for welding.

Here are some more piccys -

So hopefully the weather stays ok tomorrow so i can start on removing the panels from the Leon.
I really have to go to the tip tomorrow, got loads of crap in the back garden and although the missus isn't complaining yet i think its on the cards.

Anyway so long hopefully update again tomorrow.

 

[Cupra R]

Epic build thread mate.

Keep up the good work, really looking forward to seeing the result of all this labouring.

 

[grahams81]

Epic build thread mate.

Keep up the good work, really looking forward to seeing the result of all this labouring.

Cheers bud, can't wait to get the 4wd part finished, and get cracking on the Big Turbo Build, got loads of bits for the manifold -

I did order a t3 divided merge collector and flange but the quality is crap so gonna ditch it and make my own.
Turbo wise i've decided to go with either a FP HTA3076 or a Garrett GTX3076r with a divided 0.82a/r housing.
Just waiting to hear back from INA on discounts for turbo & clutch and i will decide if the HTA's worth the extra coin over the GTX.
Decided not to bother with the Borg Warner EFR's cos they are as rare as Hens teeth.

It's gonna be hard to squeeze 2 Tial Wastegates in but i'm sure i'll manage. Probably gonna mount the turbo slightly towards the passenger side to give me more room for the down pipe and twin wastegate pipes.

Here are some pics of a T3 Twin Scroll Manifold i found on VVortex by a company called Eurojet -

That kit uses open dump for the wastegates - i've looked into them and although open dump wastegates sound pretty awesome when your on full boost, i'm not sure if dumping redhot exhaust fumes under the car is a good idea, i will propably run them into the exhaust.
I might put a joint in just to experiment with open dumping them with a elbow towards the floor, so i can either join them into the exhaust or open if there too noisy / chavvy.

 

[Cupra R]

It's a shame to hide something like that.

I wish I were closer to you mate, I'd of loved a rod kick on the engine build (can't exactly tyre kick yet can I lol)

How long do you forsee it taking you? All things considered, have you set a goal?

 

[grahams81]

I'd of loved a rod kick on the engine build (can't exactly tyre kick yet can I lol)

How long do you forsee it taking you? All things considered, have you set a goal?

rod kick - excellent mate.

Goal wise - i havn't really set one mate - i work away from home nearly every week so can only do so much, i am aiming to have the 4wd panels in by next weekend.
Really the only restraint is money and time

Realistically though i think the car should be finished by Christmas, all things considering with all the fab work for the turbo / exhaust / intercoolers / mapping / bodywork / rollcage...... the list goes on

But it will be well worth it, 400-500hp + 4wd = Big Smiles

 

[Willie]

Are you not concerned about the lack of meat you have on the S3 section seams for welding?
Heat is going to be you enemy with possibilities for warping.

You obviously know how to weld before your making your own exhaust manifold, so please don't think I'm knocking your welding expertise.

 

[MrBen2k7]

Call this a stupid question... but...

Would you not of been better off starting with a Leon 4x4 from europe? and then getting an LCR doner car and transplanting all of that to the 4x4 one?

If I was to do this project, thats how I'd of gone about it....

Or is that no possible or just plain too easy?

 

[grahams81]

Call this a stupid question... but...

Would you not of been better off starting with a Leon 4x4 from europe? and then getting an LCR doner car and transplanting all of that to the 4x4 one?

If I was to do this project, thats how I'd of gone about it....

Or is that no possible or just plain too easy?

OH sh*t i never thought of that

On the serious note - try and source a leon 4 abroad - pretty much impossible unless your willing to spend serious money then the hassle of importing / getting log book etc and of course it would be a left hooker - so still a big job to convert it to RHD.

After i sold the 911 i decided i wanted a cheap turbo 4wd car that i could modify, i was looking at Evo 5-6's always loved them but never owned one, but then i started talking to my work mate who had his cupra with a knackered engine, i had known the car for the last 8 years and knew it would be a nice project but the only downside was the fwd, even so paid £600 and the rest is history.
After loads of reasearch i then realised a 4wd conversion could be done, same shell / floorpan design as the mk4 golfs s3's etc and there's a good couple of guys done the conversion to them.
Looking back i should have just bought a S3 / TT quattro but i love the look of an LCR don't think you can beat it.

Anyhow im off to start on the leon shell.

 

[MrBen2k7]

OH sh*t i never thought of that

On the serious note - try and source a leon 4 abroad - pretty much impossible unless your willing to spend serious money then the hassle of importing / getting log book etc and of course it would be a left hooker - so still a big job to convert it to RHD.

After i sold the 911 i decided i wanted a cheap turbo 4wd car that i could modify, i was looking at Evo 5-6's always loved them but never owned one, but then i started talking to my work mate who had his cupra with a knackered engine, i had known the car for the last 8 years and knew it would be a nice project but the only downside was the fwd, even so paid £600 and the rest is history.
After loads of reasearch i then realised a 4wd conversion could be done, same shell / floorpan design as the mk4 golfs s3's etc and there's a good couple of guys done the conversion to them.
Looking back i should have just bought a S3 / TT quattro but i love the look of an LCR don't think you can beat it.

Anyhow im off to start on the leon shell.

Fair enough. Looks like a monster project! Really is coming along nicely!

 

[grahams81]

Are you not concerned about the lack of meat you have on the S3 section seams for welding?
Heat is going to be you enemy with possibilities for warping.

You obviously know how to weld before your making your own exhaust manifold, so please don't think I'm knocking your welding expertise.

Hi Willie, thats ok mate any critisisms / ideas are all welcome.
I'm not too concerned with the lack of area for welding mate - i am drilling out the leon panels with a spot weld drill to leave as much "meat" on the leon shell, then the plan is to use the holes in the s3 part to weld to the leon parts.
I know it's hard to imagine but when you look where i will be joining, basically wheelarches / front seam above petrol tank / rear panel / frame rails.
I can access the front and back of the panels so i can weld in the spots then fully seam weld the front lip of the panel and the inside lip of the panels - gonna run weld right round the inner arches aswell.
I think it will be as rigid if not more rigid than the original shell.

Hopefully when i get the original panels out i will take plenty of pics to show in more detail.

 

[Cupra R]

It certainly will be worth it mate and I hope to see it at York Raceway or somewhere when it's finished.

Keep up the good work.

 

[betty_swollox]

Mate this project is unreal!!!

You better take us all for a spin when it's done

 

[Jacko_lcr]

this is gunna be amazing when you get it up and running always wondered why seat never did a cupra as a 4wd..... much the same as ford witht he focus rs.

anyways heres a link to a friend of mines car its a c2..... v12!!! running one v6 in the front one in the rear. http://www.pistonheads.co.uk/gassing/topic.asp?h=0&t=970287&d=0&nmt= only build link i could find quickly

the lad originally created the first v6 c2 but soon after it was finished it was destroyed in a garage fire in the unit it was kept at. so he decided to go all out and create the v12. hope this keeps your faith mate that if you keep going even when it gets difficult good things will come of it. my mates been winning car shows left right and centre

anyways keep up the good work mate and good luck it will be amazing when finished and just keep thinking of that first bottle of larger when you finish the car after all the months and hard work while your standing back and looking at the car youve created the work youve done. and if the worst does happen and you dont complete the car dont look at it as failure look at it as a learning curve on what you did right and what you did wrong and transfer that knowledge onto your next car as your knowledge is your best tool.

Jacko

 

[grahams81]

Cheers Jacko for the supporting words, really appreciate it mate.
I still can't believe the support on this forum, by far the best forum i've ever been a member of.

Just had a read of your mates c2 build thread, its totally awesome, absolutely love stuff like that. Makes my build look a bit tame !!!!

Well there's no turning back now, i started on the cupra shell this morning drilled out the spot welds (using a spot weld drill bit to leave the rear face intact) in the wheel arches, i started to remove the seal sealer from the boot floor and it was a serious pain - not the same as the normal stuff.
Once i got the seam sealer of it appears i may have been rear ended at some point !!!! thats obviously why the seam sealer was a different type.

Pics of the bodged back panels -

Also removed the spot welds from the rear panel that joint the back panel to the rear frame rails -

Rain has stopped play at the moment but hopefully get back at it later if it drys up.