Hayden and Cliffos Mk4 R32 build

[dylan8]

Keen to see if the brake ducts work. 18kg is a lot considering you haven't really taken any items or features away.

[Lucas_R]

Nice progress on the 32 Hayden. Good luck this weekend. Stay safe.

[HaydEn]

Keen to see if the brake ducts work. 18kg is a lot considering you haven't really taken any items or features away.

Road test shows not as effective as I thought, but slow speed and heavy braking isn’t the best test scenario.

Yeah exactly right. I’ve maintained the factory fuse box that sits on top of the battery as well, just used a stud terminal to join the battery in the back to it and the starter.

With all the accessories on, wipers, lights, radio and fans voltage drop was minimal.


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[HaydEn]

Nice progress on the 32 Hayden. Good luck this weekend. Stay safe.

Thanks man. Hopefully both back in one piece!


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[HaydEn]

ABSOLUTE STITCH UP


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[HaydEn]

Well the nationals supersprint didn’t go so well.

Started the week off by snapping the inner CV joint cage on my way to work in my daily.

So was forced to drive R32 and finish up bits and pieces in between. Then comes Friday driving down to Accomodation. Sitting in traffic, clutch pedal straight to floor, happened another 3 times! Typically, after I changed the o rings. It has been fine for 8 months. Day before track day plays up!

First session, 6 laps in, just getting a feel for the car with the changes since the previous year as well as the temperamental clutch pedal, disaster strikes going through a pretty quick sweeper.

Car got real lose and all over the track. Pulled off and seen smoke coming from the back wheel, tyre looked flat at the time (must have parked on a rock in the grass or something) so not ideal, but not the worst outcome.

Start driving off to the pits and there’s some loud grinding noises and no brakes. Well that’s not a tyre issue, get back to the pits, notice the caliper has taken a fair hit from the rotor.

Started pulling bits off to investigate and all things started pointing to loosened driveshaft bolt or collapsed bearing.




Pulled out the driveshaft bolt and found this dodgy spacer


Spot the issue


Something even more unbelievable, sheared/snapped the snout off the hub.



Turns out, dodgy as previous owner. Cheaped out and replaced the hub with a non R32 item. Which relies on the the driveshaft spline supporting the inside of the snout. Because he didn’t swap the outer cv to the nut style the hub was unsupported and eventually sheared under load.

Thanks to Trickysimon being a good bloke for once in his life, swapped his and Zalemate’s car’s around on the trailers and towed the R32 back up to Newcastle that night. Back down for a quick sleep and off to the show on Sunday!

Silver linings of all of this.

Went 1.2 seconds faster than last year during warm up.
Didn’t happen under a big brake zone and/or lose a wheel and wreck the car more.
Didn’t happen on the street and kill someone.



Couple of dead VW’s


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[HaydEn]

Time to rebuild.

Starting with hubs and bearings, couldn’t find any in Australia so had to go through ECS, because of the ridiculous shipping, might as well load up and fix a few things that have been causing grief or I have been to lazy to do because it still worked ok.

So ordered 2 new hubs and bearings, solid front subframe bushings, solid power steering rack bushing and ECS alloy bleeder block for the clutch line.



Convinced myself I might as well change the old clutch line and then the whole system is new parts, so ordered a braided clutch line from 034. So at this point most of the car would have been sorted, but if the front end was going to be solid mounted, the rear should be too



And then because I had gone this far I might aswell get some more camber and caster out of the limited front end, with some silver project camber tops.

Following that, I had started to have a long pedal travel and bigger is always better??

So grabbed some 17z calipers, braided lines, EBC blue stuff pads and because they were on sale DBA two piece rotors




And then some H&R sway bars..



And to cap it off. A half cage + door bars





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[HaydEn]

In the last 2 months with collecting bits and pieces I’ve slowly put them onto the car. Starting with the easiest being brakes



This started obviously issues! Doesn’t clear wheels with out a 30mm spacer, which makes them stick out far to much. Grabbed a set of wheels from Trickysimon at Nationals that we’re going to be daily wheels

They clear a little bit better. But hit the inner barrel, so I will need to do some ‘machine’ work if ever intend to use them.
I have only just got around to rectifying the wheel issue in the last week or two by ordering some Team Dynamic wheels from the UK, so that will be a 10-12 week wait.

Continuing on.

Front subframe bushings, pressed in with the Milwaukee. Tyrolsport items should be good with how tight they are.


Tyrolsport solid steering rack bushing, these I assume are meant for RHD so the bracket for the power steering lines doesn’t work and needs to be cut off.


H&R front sway bar in


Not sure if I need to spend the cash on adjustable end links or not at this stage as one half of the joints are maxed out. But I intend to buy new coilovers so will probably just wait it out.

Silver project camber tops in.



Also decided to make the switch to studs


Bought some delrin shifter bushings as the forward/aft bushing had completely separated which was causing the grinding into 3rd (I knew it wasn’t my driving!)


Onto the rear bushings, had to make up a tool to get the stock bushings out


Powered by the Milwaukee, made short work of them. Except for deforming the alloy pipe I used


And new solid ones Milwaukee’d in


Put the H&R sway bar in at this time as well but didn’t get a snap of it.

Plan all along was to get a header and 3” exhaust to get rid of the crap stock stuff, now is a better time than ever!

Bit of a mission to cut out with an alloy cutting disc but got there in the end

Header sneak peak.


Only thing left to do is exhaust and brake master cylinder upgrade. Because of the 6 pots I want something more than the Factory sized item.

This means modifying the booster casing!




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[sambb]

Far out, some serious hardware updates there mate! Are you doing those extractors yourself? they look unreal.

[HaydEn]

Far out, some serious hardware updates there mate! Are you doing those extractors yourself? they look unreal.

Yeah gone a bit over what was required, but should last the live of the car now and really transform it.

My mate is doing them for me.


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