Stan's Epic Golf Build: 1.6se becomes 1.8T

**Stan** · 25-11-2011, 05:53 PM

Stan's home made bash plate:

3mm aluminium checker plate:

Fixed to car with double sided tape and clamps - trace around for shape:

Cut out with a jigsaw fitted with an aluminium cutting blade (yes they make ones just for that!):

Mark in half the width of the bottom lip, and drill screw holes every 100mm or so, also stick double sided tape along this line (overkill, but it stayed on)

Stick and screw it on with self tappers:

Unseen here is a tie point from the centre of the rear edge to a bolt hole in the motor - held with beefy cable ties at first. This stops it from flexing and wobbling across the back edge.

Then sprayed the front edge.

How does it work?

Awesome! In fact too good. Scrapes are fine, but if you as much as bump a fixed object there is absolutely no give at all and all the force is transmitted through the bumper. This causes the mounting points to fracture and stress cracks in the bumper. A heavy scrape will do this as well - so in some ways - no better off.

I have now repaired and repainted this several times, and the final solution for now will be this: Bloody thing is coming off and the original is going back on - for now.

I'm going to take a 2 inch section out of it and see how it goes. It is flat across the front though , so any approach that causes a touch is almost always a direct hit, so we will see.

There is also a cunning plan to section it and if it still causes grief to recast it in ABS plastic..not as tough as it sounds, or so my feeble mind tells me - ingnorance is bliss (it must be or this project would never have got off the ground...)

So, coming up - big brakes go on (car in the garage at the moment waiting for caliper carriers to finish that one), old bumper back on and remodelling the 'glass bumper...

---------- Post added 25-11-2011 at 06:53 PM ---------- Previous post was 19-11-2011 at 10:46 PM ----------

Big brakes are now on and the original front is back on - the other one was just too impractical for daily driving.
Some pic updates are on the way soon

**Water Boy** · 25-11-2011, 06:07 PM

Well done Stan for finishing the conversion. IMO the stock bumper is so much better looking and doesnt give any hassles with low drive ways, much better.

Keep up the good work.

**Stan** · 25-11-2011, 09:23 PM

Thanks mate, yep the Regula brand bumper isnt for everyone - back to stock for now...

ok so big brake upgrade time:

1.6 brakes are not big enough, so it was GTI or Audi TT for me, as those were the parts I had.

I had GTI calipers and carriers, but no hubs, and TT calipers and hubs but no carriers - so decided on the TT items.

incidentally the carriers and hubs for the 1.6 are a combined unit

Also calipers and pads for the mk1 TT and the mk4 GTI are the same.

Carriers were $260 EACH from the stealers and $99 from ECS - no used items from Audiwreck and the like - and they would only sell complete units. Seb and Courtney from Euro Revolution to the rescue with an order from the States

My TT ones (gold) vs GTI - a bit bigger due to larger rotor size:

You have to pull out the whole strut and hub assembly to change it all over. Nice guides on vortex and UKmkivs
Oh, and undo the 30mm axle nut (single use item) before you jack up the car - they are torqued up TIGHT.
Essentially take off the caliper and hang it out of the way.
Remove the strut and hub setup - undo steering ball joint, lower control arm ball joint, and pull it free of the axle stub - get a puller for this if tight.
When it is all out swap the calipers - more space and easier to catch the brake fluid spills and clean them up (we dont want stripped paint and rust now, do we?)
Replace the hub (good time to do wheel bearings), and stick it all back in
The carrier and caliper just bolt on the back with 2 bolts - so easy I can do it.
Dont forget ABS sensors and pad wear connectors.
The ABS sensors from the 1.6 bolted straight into the TT hubs, I imagine the same unit for all.

1.6 rotors are 280mm
GTI are 288mm
and TT (mk1 FWD) are 312

The rears for all these models are the same at 232mm - so they stayed in.

1.6 vs TT:

The TT rotors will fit behind a standard 16 inch GTI wheel

New ones in:

You could paint them to make them look pretty, but I didnt have time (daily driver...), I might later on.

So it all looks like this now:

Check those rotors:

Spacers to come...

**Water Boy** · 25-11-2011, 09:41 PM

Some all red tails like Matt's would go well:

**Jace** · 26-11-2011, 11:37 AM

Nice sleeper, I'll see you torque-steering around town soon.

**Stan** · 26-11-2011, 02:49 PM

Red tails on red might be a bit much - but interesting idea. i actually like the aftermarket hellas on it. Blacked out oem might look good too. I like the debadged look of Matt's car, and might make my VW badges match the wheels in a metallic grey...

Thanks Jace, after looking at a few build threads now, mine seems a little tame - but for me sleeper is good.

**Jmac** · 26-11-2011, 07:38 PM

Looks like you are having fun with it now Stan, Good work, glad the wiring help gave it the minerals, sorry keep calling then the minerals but have done for years. Anyway, keep up the good work mate.
Jmac