FraggyTDI
Veteran Member
Hello All,
My name is Chadwick and I just came into possession of a 2003 Golf with 280k miles on it. I traded a dirt bike for it so as far as I'm concerned it's a good deal. The vehicle body is in steller shape for it's age not a spec of rust and only some very small dings in the body.
I'm starting this thread to track the progression of this build and to hopefully provide guidance and a what to and not to do for others in this forum. Now I'm no professional engine builder but this will be my 3rd engine tear down and rebuild. My first being a 2.0T Audi which when I started this engine tear down it was a breeze as it's essentially the same setup as the 2.0. It took me about 6 hours to pull the engine and strip is down the engine to bare bones.
Currently everything is disassembled and the block is at the machine shop for a bore and hone. The cylinder head is disassembled and cleaned. I've now began porting/cleaning. Basically everything will be replaced on this engine.
My overall goal, create a reliable stout engine that provides fun and good gas millage. Goal hp is around 300+ obviously with higher horsepower I start to sacrifice reliability but I will access so risk as they come.
Game plan:
Cylinderhead
Rebuild head
New valves
Upgraded cam (still in decision Frank06 or Colt)
Ported
New Cam followers
ARP head studs
Considering getting cam and followers cryo'd out of curiosity
Block
.5mm overbore
honed
hot tanked
Decked (will move up to 3 hole gasket)
Painted
New Nural AHL pistons (This may be a weak point that needs to be accessed)
IE Rods Rifle drilled
New bearings all around
ARP Mains
Girdle
BRM Oil sprocket
New oil chain and tensioner
New seals all around
Transmission
Ryan P 6-speed swap
LSD
HD Clutch
Performance
Upgraded Nozzles (dependent on Turbo)
GTB 2260-2566VK (Still deciding need to run numbers)
Upgraded Intake (not sure what to get here, might design my own)
FMIC or Water to air cooler\
3" exhaust to dual 2.25" out the rear
Suspension
Koni SRT's
New balljoints
TT bushings
New tie rods
Body
Wrapped or painted Nardo Grey
Avant Garde wheels
Engine will be painted to match wheel color
So this is my Goal I'm building this car to be with me for life and I know it's going to cost a lot in some respect but considering I was just about to buy a $22K audi that I would of dropped money into as well I feel I'm saving myself money and getting exactly what I want. I might of missed some things. I'll update this thread as I progress. My goal is to be hopefully running by the time the snow melts. Not complete with everything but engine and tranny in so I can begin the break in period.
My name is Chadwick and I just came into possession of a 2003 Golf with 280k miles on it. I traded a dirt bike for it so as far as I'm concerned it's a good deal. The vehicle body is in steller shape for it's age not a spec of rust and only some very small dings in the body.
I'm starting this thread to track the progression of this build and to hopefully provide guidance and a what to and not to do for others in this forum. Now I'm no professional engine builder but this will be my 3rd engine tear down and rebuild. My first being a 2.0T Audi which when I started this engine tear down it was a breeze as it's essentially the same setup as the 2.0. It took me about 6 hours to pull the engine and strip is down the engine to bare bones.
Currently everything is disassembled and the block is at the machine shop for a bore and hone. The cylinder head is disassembled and cleaned. I've now began porting/cleaning. Basically everything will be replaced on this engine.
My overall goal, create a reliable stout engine that provides fun and good gas millage. Goal hp is around 300+ obviously with higher horsepower I start to sacrifice reliability but I will access so risk as they come.
Game plan:
Cylinderhead
Rebuild head
New valves
Upgraded cam (still in decision Frank06 or Colt)
Ported
New Cam followers
ARP head studs
Considering getting cam and followers cryo'd out of curiosity
Block
.5mm overbore
honed
hot tanked
Decked (will move up to 3 hole gasket)
Painted
New Nural AHL pistons (This may be a weak point that needs to be accessed)
IE Rods Rifle drilled
New bearings all around
ARP Mains
Girdle
BRM Oil sprocket
New oil chain and tensioner
New seals all around
Transmission
Ryan P 6-speed swap
LSD
HD Clutch
Performance
Upgraded Nozzles (dependent on Turbo)
GTB 2260-2566VK (Still deciding need to run numbers)
Upgraded Intake (not sure what to get here, might design my own)
FMIC or Water to air cooler\
3" exhaust to dual 2.25" out the rear
Suspension
Koni SRT's
New balljoints
TT bushings
New tie rods
Body
Wrapped or painted Nardo Grey
Avant Garde wheels
Engine will be painted to match wheel color
So this is my Goal I'm building this car to be with me for life and I know it's going to cost a lot in some respect but considering I was just about to buy a $22K audi that I would of dropped money into as well I feel I'm saving myself money and getting exactly what I want. I might of missed some things. I'll update this thread as I progress. My goal is to be hopefully running by the time the snow melts. Not complete with everything but engine and tranny in so I can begin the break in period.
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