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Grahams81-Leon 4wd, Big Turbo - Back in the saddle :-)
- Thread starter grahams81
- Start date
Stefal639
Guest
I totally understand what your saying about price. I had the same thoughts and did the same investigations as you have with the same results found on the same forum.
After this my thoughts stand, VT all the way. Try www.clubgti.co.uk, their for sale section is very good.
I have not experience of the inserts you speak of.
After this my thoughts stand, VT all the way. Try www.clubgti.co.uk, their for sale section is very good.
I have not experience of the inserts you speak of.
Laundrymike
Guest
Just read this from the start, incredible project and hats off to you for doing it on your drive!
Sorry about the lack of updates lately, been away for a fortnight with work with hardly any internet access 
Thanks for the comments guys.
Traveling back through the night tonight so gonna have a 4 day weekend, so i will have plenty of time this weekend to get stuff done, thats if the rain holds of........ Really wish i had a double garage.
Stay tuned for updates this weekend. So long for now.
Thanks for the comments guys.
Traveling back through the night tonight so gonna have a 4 day weekend, so i will have plenty of time this weekend to get stuff done, thats if the rain holds of........ Really wish i had a double garage.
Stay tuned for updates this weekend. So long for now.
Well although we had a couple of wet days i managed to get a bit done on the shell this weekend.
After checking and double checking dimensions and ensuring the back was sitting square i welded up the inside frame rails that i had to cut, welded them together and then put a plate over the top of the joint and welded them on.
Had loadsa bother with my MIG welder, they really don't like welding upside down and the tip kept getting clogged, tried loads of different settings but struggled a bit. Didn't help it was blowing a gale (blows away the argon from the weld and makes it react).
So today i got the sections back in of the chassis rails i removed (for access to the frame rails behind)
Decided to TIG these as its so much more controllable -
Really hard welding upside down, doesn't look too pretty but i made sure i had good penetration
So the chassis rails nearly completely welded now (just got to fill up the old Spot weld holes with the MIG), that was the hard bit i wasn't looking forward too but its done now...
Hopefully get most of the welding finished off next weekend, still got to do the wheel arches and inner boot floor to do. Also got to make a new back panel (probably gonna mate the Audi S3 part to the original shell (doesn't have to be pretty as its covered by the bumper just functional).
Sorry for the lack of photo's at the moment - the project is at that stage where although i can spend days working the car pretty much looks the same....
After checking and double checking dimensions and ensuring the back was sitting square i welded up the inside frame rails that i had to cut, welded them together and then put a plate over the top of the joint and welded them on.
Had loadsa bother with my MIG welder, they really don't like welding upside down and the tip kept getting clogged, tried loads of different settings but struggled a bit. Didn't help it was blowing a gale (blows away the argon from the weld and makes it react).
So today i got the sections back in of the chassis rails i removed (for access to the frame rails behind)
Decided to TIG these as its so much more controllable -
Really hard welding upside down, doesn't look too pretty but i made sure i had good penetration
So the chassis rails nearly completely welded now (just got to fill up the old Spot weld holes with the MIG), that was the hard bit i wasn't looking forward too but its done now...
Hopefully get most of the welding finished off next weekend, still got to do the wheel arches and inner boot floor to do. Also got to make a new back panel (probably gonna mate the Audi S3 part to the original shell (doesn't have to be pretty as its covered by the bumper just functional).
Sorry for the lack of photo's at the moment - the project is at that stage where although i can spend days working the car pretty much looks the same....
Complete admiration for the work you're doing Graham! Achieving what others have dreamed of! Really enjoying the thread so far. Hopefully you'll be showing it off in the flesh next year once it's done.
Keep up with the updates mate
James.
Keep up with the updates mate
James.
Hi Ronin, i havn't bought one yet mate - thats gonna be a bit in the future i think.
Have not even got any suspension yet or brakes or intercooler or well you get the idea...
Trying to spread the cost of stuff out at the moment, so i paid for the turbo last month (still have not got it yet tho, has not been released by Borg Warner yet
)Trying to by stuff as i need them, so next will be PU bush set for the suspension before it gets fitted.
Complete admiration for the work you're doing Graham! Achieving what others have dreamed of! Really enjoying the thread so far. Hopefully you'll be showing it off in the flesh next year once it's done.
Keep up with the updates mate
James.
Cheers James thanks for the encouragement, been feeling guilty lately due to the lack of updates - i know you guys like the updates with the piccys and i've been really busy with work.
Stay tuned next weekend for another update.
Tata.
Looking great.
Have you tried the gasless MIG wire?
That might help with your upside down welding issues.
Looking great and really well done for tackling this project but I know from experience there is still a lot of work still to be done.
Do you have a garage you can work in when the weather gets rubbish during the winter or is the plan to have it wind and water tight before then?
I will probably do an independant rear suspension set up for mine but wouldn't go 4WD as I don't feel like I would benefit from this or the extra weight.
Fair play to you though this will be a great learning curve for you and us.
I know that people don't like to advertise their issues or feck ups.
I have in my readers rides section in the hope other will read this and learn from them.
If you could it would be good to hear yours too but understand if you don't want to advertise them
Have you tried the gasless MIG wire?
That might help with your upside down welding issues.
Looking great and really well done for tackling this project but I know from experience there is still a lot of work still to be done.
Do you have a garage you can work in when the weather gets rubbish during the winter or is the plan to have it wind and water tight before then?
I will probably do an independant rear suspension set up for mine but wouldn't go 4WD as I don't feel like I would benefit from this or the extra weight.
Fair play to you though this will be a great learning curve for you and us.
I know that people don't like to advertise their issues or feck ups.
I have in my readers rides section in the hope other will read this and learn from them.
If you could it would be good to hear yours too but understand if you don't want to advertise them
Brilliant, as always. Look forward to seeing that end product!! Welds look pretty good for upside down it's something I need to learn to do really. How long before you hold the turbo then?
it's something I need to learn to do really. How long before you hold the turbo then?Alright willie, i did originally try the gasless MIG wire but found it too hard to use on thin metal, your right though it would have been better outside with the wind etc.
I have used half a bottle of argon over the weekend as i was using quite a high flow rate on the TIG to keep the reactions at bay.
Unfortunatly i have only got a single garage and thats full now with the engine on stand, engine lift, 2 motorbikes etc. So my plan was to get the external welding etc done before the weather gets too nasty andthen i can work inside the shell to finish of welding all the spot welds up etc. Really need to get a rush on as the weather is getting crappier every weekend...
And don't worry i will let everyone know my feck ups ! The first page contains one trying to press a main bearing clamp over a socket
For others thinking of doing this i would recommend only attempting if you've got a double garage or access to a workshop ( its doable out side like me but i'm loosing so much time when its raining and im only back to work on the car on weekends so its a pita) and of course not too shy about cutting big lumps out of your pride and joy.
Not sure if i would go through all the bother just to run independant rear suspension, i will try and weigh the diff assembly up once ive stripped it so you guys can judge how much weight you would be adding by running the 4wd system.
Cheers for the comments Joe, at the moment the release for the Borg Warner EFR's Twin scroll with internal wastegates seems to keep getting pushed back.... Last update i got from treadstone performance was September / October time, not really too bothered at the moment gonna try and concentrate on the chassis and my roll cage came last week so still got that to put in - it would be nice to get my grubby little mits on it tho
and of course take some pictures for you guys !!!
I have an A4 S line TDI. It has double wish bone suspension with independant rear.
My mate has a MK2 Leon Cupra with independant rear suspension.
I have driven both in full OEM spec and the handling difference with the OEM LCR is night and day.
The MK2 Leon Cupra and the MK2 S3 were within 0.5 sec a lap of each other in a magazine.
With the sort of power levels I'm currently and planning to run I doubt the extra weight and 4WD system would give me much benefit. Also if/when I start racing it will put me into leagues with the big boys.
I totally understand the want and need for 4WD with big power and wet driving etc.
Onwards and upwards my good man!!
My mate has a MK2 Leon Cupra with independant rear suspension.
I have driven both in full OEM spec and the handling difference with the OEM LCR is night and day.
The MK2 Leon Cupra and the MK2 S3 were within 0.5 sec a lap of each other in a magazine.
With the sort of power levels I'm currently and planning to run I doubt the extra weight and 4WD system would give me much benefit. Also if/when I start racing it will put me into leagues with the big boys.
I totally understand the want and need for 4WD with big power and wet driving etc.
Onwards and upwards my good man!!
Two words! Respect and inspired mate!!! I would love to build a project like this! Altho i'd probably start with an s3 and just lob the twin scroll in that! Lol! How did you learn to do all of this? Most daring thing I've attempted on my car is to replace the tumble flap motor (piece of piss)! Would a nvq mechanics course be a good start???
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Have to say this is excellent
Looked into doing this myself.
Spent a whole day on vagcat.com comparing the part numbers for all the various 4x4 MK4 platform cars (A3 Quattro, S3, TT, R32 etc) with the Leon 4.
Plan was to get a damaged S3/TT and transfer the rear floor / drivetrain to my LCR.
Then I would have sold the engine and other bits I didn't need. That way the parts I would have kept would have effectively been free
Only problem was I don't know how to weld, and a workshop would charge way too much to do it!!
From my research I noted that the rear apron is different on the 2wd & 4wd Leon, as are the rear arch liners. The part numbers and prices (from Sere motors) are:
Inner arch liner (L): 1M6 810 971D £30
Inner arch liner (R): 1M6 810 972D £30
Rear apron: 1M6 813 303J £28
Prices were correct as at Feb this year. David at Sere said they take about 7-10 days to arrive as they have to come over from Spain.
Looked into doing this myself.
Spent a whole day on vagcat.com comparing the part numbers for all the various 4x4 MK4 platform cars (A3 Quattro, S3, TT, R32 etc) with the Leon 4.
Plan was to get a damaged S3/TT and transfer the rear floor / drivetrain to my LCR.
Then I would have sold the engine and other bits I didn't need. That way the parts I would have kept would have effectively been free
Only problem was I don't know how to weld, and a workshop would charge way too much to do it!!
From my research I noted that the rear apron is different on the 2wd & 4wd Leon, as are the rear arch liners. The part numbers and prices (from Sere motors) are:
Inner arch liner (L): 1M6 810 971D £30
Inner arch liner (R): 1M6 810 972D £30
Rear apron: 1M6 813 303J £28
Prices were correct as at Feb this year. David at Sere said they take about 7-10 days to arrive as they have to come over from Spain.
Cheers for the comments mate, I'm a Maintenance Engineer by trade but i've always worked on cars and bikes as a hobby, during my apprenticeship i did loads of machining / metal work / welding etc so got the basic skills years ago.....
I've got to admit i'm not fearless - i did find it dawnting cutting the floor out.... but no matter what you do there's normally people on the internet that have done it already, research everything - use everyones knowledge to your advantage.
Haynes manuals etc are brilliant, just being an engineer doesn't mean you automatically know how to strip something down (although i have found just loosening bolts and shaking quite a good method
)I suppose a NVQ in mechanics would be a good start, as for things like welding - just go and buy a welder and plenty of bits of scrap metal and just practice...i found a really good website for tips etc
Here is a pic of my welders -
Welding Website - http://www.mig-welding.co.uk/mig.htm
The website contains tabs at the top for different forms of welding, MIG/TIG/ARC etc.
You can be good enough for the job of welding panels etc in a couple of days, just follow the guides and watch some films etc.
Maybe don't start cutting your car up quite yet but you get the picture ?
Have to say this is excellent
Looked into doing this myself.
Spent a whole day on vagcat.com comparing the part numbers for all the various 4x4 MK4 platform cars (A3 Quattro, S3, TT, R32 etc) with the Leon 4.
Cheers bud, thats the exactly the same as i did - sat trolling VAGCAT and the forums for info, comparing part numbers with s3's TT etc.
Anyhow time for an update, went with the missus for an early scan on Saturday and we had some good news she's 8 weeks pregnant
Afterwards went for a meal and then to see the inbetweeners to celebrate, got nothing done on the car but got to keep the boss happy...
Anyhow did a couple of hours this morning just finishing off welding along the sill edges and generally tidying up the welding, gave it a good going over with a wire brush in the drill and sprayed some etching primer on... then had to go round me mother-in laws for dinner.
Anyhow came back full but managed to get a couple of hours in before dark, used my brushable seam sealer and set to work covering up the chassis rails -
Gave the sills a lick of sealer as when i was welding the other side the original stuff set on fire -
So i'm getting there, slowly but surely, got a week off work soon so will hopefully make some good progress.
Heres a couple of shots of the cage, there not too good as there's loads of stuff in the garage at the moment -
Getting the cage in will be the next job on the long list......
Anyhow so long for now,
Graham.
Congratulations on you impending arrival.
Its a great new word post baby.
Hopefully you get this project finished before the little one arrives as everything will be more tight after.
Its a great new word post baby.
Hopefully you get this project finished before the little one arrives as everything will be more tight after.
Cheers Willie, your right gotta get my finger out and get done. 7 months and counting
Back from work now so gonna get cracking.
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