Thai's grey mk1 Cupra R

[Sparkie]

This is where I'm currently at with the latest lump.
All ancillaries were removed, block has been deep cleaned and painted black.
Yellow rocker cover swapped for another freshly painted grey one with new stainless fixings and new Elring gasket.
Oil filter housing, ancillary bracket and engine mount bracket all painted grey to match.
Fluidampr and cambelt covers have been freshened up with tough satin black paint.
I'm just awaiting a few more gaskets and seals then it can go back together fully.

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Very crisp.
Like that lots.


Badger5 Custom Map + TIP,
3”Custom exhaust, FMIC, Bosh 550’s, BC Coilovers, ARB’s +loads more.

 

[Thai-wronghorse]

Cheers, I've put a fair few hours into tidying up so far...not that it was a mess as it had only done about 7k since it was built by Badger 5 and its previous owner.
Fingers crossed some more bits arrive this week so I can crack on with the rest.

Current dilemma is how to finish the SEM manifold and which throttle body to run.

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[Thai-wronghorse]

Annual workshop panic goes into effect now as I prepare for December shut down.
This can only mean more focus on putting my own car back together so that's what I've been doing the past few days along with a few more shiny deliveries and odd and sods cleaned up and painted.


CSF full alloy race radiator
VDO hemi 80mm throttle body
Alloy MAC 3 way valve bracket
A large selection of new coolant hose spring clamps
New Lucas alternator & auxiliary belt.

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[Thai-wronghorse]

And more bits thrown onto this lump...

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[Thai-wronghorse]

Not so shiny broken bit found!

Replacement servo on it's way as I type.

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[g60stu]

All your car bits look so shiny!!
How much does an alternator cost these days?
And I’m curious - will you use a washer (fibre or copper) on the radiator temperature switch?? I’m about to change my rad when I overhaul my a/c system soon.

 

[Thai-wronghorse]

I didn't actually need an alternator as ive got a few working ones in stock but none that looked clean enough to go on this engine.
I initially stripped one down for painting but ended up damaging it on reassembly so thought sod it, just buy a shiny new one instead.
Prices vary quite a lot but I went with a mid range one from Lucas who are very reputable brand. It was about £200 but I got £72 surcharge back by palming off my destroyed one to the lad at ECP.

I haven't even taken the rad install into consideration yet so can't comment on the temp sensor yet.

My replacement servo arrived today so that's been fitted along with another cleaner master cylinder, fluid has also been topped up and all 4 corners bled again whilst access is easy. Fingers crossed I only have to bleed the clutch line once the engine & gearbox go back in the bay.

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[England]

Lovely car, and platinum grey is the best colour. Reminds me of my platinum grey that I had, also around Maidstone GF54 DYW. Loved that car! Good luck with the rebuild.

 

[Sparkie]

Only slightly jealous.


Badger5 Custom Map + TIP,
3”Custom exhaust, FMIC, Bosh 550’s, BC Coilovers, ARB’s +loads more.

 

[Thai-wronghorse]

More bits attached and added for mock up purposes only.

Replacement brake servo and master cylinder fitted.

Vibratecnics engine mounts bolted on.

Additional thermomet heatshield on the firewall, this might get changed yet but its what I had to hand at the time.

I've also done most of the engine wiring loom modifications, repairs and tidying up now (that was a days work in its self!)

I really want a new charge pipe and TIP fabricated but I'm struggling to find anyone local that can do the work to a decent level .
I did contemplate hacking up my Trackslag K04 charge pipe up as it does look good but I'd rather it was straight than kinked towards the turbo as it'll likely interfere with my strut brace plus it'll mean the heatshield on the rocker cover will need to be shorter as well which kinda defeats its purpose.

 

[Thai-wronghorse]

Brand new Sachs SRE 4 puck paddle clutch & Sachs clutch release bearing which have now been fitted along with the freshly painted rebuilt gearbox. (More pics to follow)

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[Thai-wronghorse]

More pieces of the jigsaw arrived today so wasted no time in fabricating a better heatshield for the charge pipe and firewall.
Just need to wrap some more thermomet around the alloy plate, it probably doesn't need it but more the merrier and it'll also look prettier...hopefully get that sorted tomorrow.
I'm quite pleased with how it all turned out really. The firewall heatshield took considerably longer than expected but it now covers more of the AC and brake lines plus I've also wrapped the power steering hose in an old chopped up coil pack loom cover then made an additional cover bolted onto the rack so that should all be protected from the downpipe now.
Whilst I was in the vicinity I test fitted my new 45° heater matrix elbows...hmm not so sure about those, they don't feel as secure as the originals which doesn't fill me with much confidence at this point.

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[Thai-wronghorse]

An unusually quiet day at work yesterday so it gave me the opportunity to mock up my front end and let's just say that took considerably longer than expected!
I'd already previously discovered my new CSF race radiator was going to cause fitment issues if I was going to retain the AC condenser but this bow had a knock on effect with the FMIC as I'll be using the larger 76mm Toyosports "Wellycooler " core instead of my original 63mm Airtec set up.

Much head scratching and fabrication ensued... ‍

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[Thai-wronghorse]

New AC condenser arrived, straight out the box and bent it up to fit

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[Thai-wronghorse]

Engine and box are in the bay, jeez that was much harder than anticipated due to the combination of having Nortech downpipe pre-fitted, AC pipe up front and subframe in situ.
In / out / in / out several times then once I'd managed to kinda get it in place I couldn't get the downpipe I'm so ended up removing it, taking the turbo back off, clocking the housing, rerouting the lines etc etc - Absolute ballache!
I'm still not happy with how it's all sitting as everything at the back us just so tight and making contact with the heatshield and firewall.
I spent far too many hours shuffling it all around to the point I'm like sod it, get the ******* together and let someone else sort it as I've had enough of that bit now.

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[Thai-wronghorse]

Holy moly i can't believe it's almost a year since I last updated this thread.
A combination of working away from home a lot, focusing on making some extra coin via breaking these cars rather than putting them together really has taken its toll on this project. Then throw into the mix a demanding daughter who expects her dad to chaperone her all over the country for various gigs it means I barely touched the Leon unfortunately.

Until this week!

I had a couple of days holiday to use up plus with the impending shut down of my workshop for Christmas it means the Leon needs to be mobile again so time to crack on...

Subframe, ARB, wishbones, steering knuckles, splash guards & associated fittings all completely stripped down and powdercoated in satin black.
Fresh Superpro poly bushes fitted to the wishbones, steering rack ARB.
Powerflex black series poly bush refitted to the subframe.
Brand new wheel bearings, ball joints, hubs, ABS sensors and genuine VAG bolts used to reassemble.
I also tarted up the steering rack, painted the track rods and installed new ends.
Both driveshafts were stripped down, cleaned, re-greased and painted.

All parts mentioned have now been bolted onto the car so at least I can roll it out if the workshop next week.

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[Thai-wronghorse]

Oh and I've also picked up a swanky new to me parts & parcel hauler, which im actually loving.

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