JP's little project

[GTphil]

That paint job on the box is very smart, overall a really good thread and build, lots of attention to detail.

[JP Racing]

That paint job on the box is very smart, overall a really good thread and build, lots of attention to detail.

Thanks for that it was done in BMW sparkling graphite with a rattle can it has come out well

[JP Racing]

Little update its coming along slowly as I've been mental at work but all going well will be up and running again before national day

Few pictures of my subframe which had been shot blasted and seam welded and powder coated so its ready to go on the car now

[jesus in the seat of a 5]

That's lush jonathan... ive had a moment...

[Os8472]

Subframe looks great fella, all the welding should help no end

[TNT ANDY]

Outstanding as usual JP, now Chop chop - Should I break down on the way to national day this year, I want to be rescued by this please.

[JP Racing]

Another little update gear selector all in

[JP Racing]

Also got a second set of 560cc injectors all in place with new seals fits well hopefully will seal ok



Scoff has told me he will be finished with the drive shafts this week going to sort out the engine mounts tomorrow and hopefully be fitting the engine in a week or so. National day isn't far away now so hopefully pull my finger out and get it done

[JP Racing]

That's lush jonathan... ive had a moment...

Luckily for me the sub frame is wipe clean lol

[TNT ANDY]

Luckily for me the sub frame is wipe clean lol

Good work Jp - keep it coming fella.

[HAndy]

looking really good mr jp

like the exhaust bracket also

you might even find your leather gaiter and surround will fit over the selector casing

[JP Racing]

Yes Andy it fits fine

[JP Racing]

Quick update again I had a few hours to spare today so I got my gearbox on so I can now get on with making the new engine mounts

[Tutuur]

See the pics for the first time now, completely missed out!!

How's the car doing now mate?

Also, what is the outer diameter of those ebay vw shafts?

[JP Racing]

Ok so I decided to take a little time away from the car for christmas to spend more time with my family. I had fun but now just want my car back on the road so decided to make a start ready for this coming year.

First job was to refit my shiny new sub frame





Seems to have gone in well next job fit the new O2M box to the block with my new flywheel and clutch.

Heres one i did earlier. Then started fitting it



It went in really quite easy and only needed a few adjustments for it to sit well on the new engine mounts.



I got a bit carried away and have just checked that most bits fit where i want them to like the new long chargecooler that ive had made fits perfectly in place. Same with the second set of injectors on the manifold all seems to fit well. Dropped the turbo in place too to make sure its ok and it seems fine just need to spin the housing round to where it needs to be.



Just need a bit more time to sort a few other bits out then hopefully i can get everything refitted more to folliw soon

[Nad-5GTT]

Just read the whole thread, you've done some excellent work and should be proud of the results, keep it up.

[B18ftMOJO5]

great project thread, great work looking forward to seeing the finished article now.

[Tutuur]

Finally some progress again, i was wondering where you were but glad to read you spent some quality time woth the family

You won't regret the 02m conversion! I've been hamering it to death but it doesn't give in! I've only torn one of my engine mounts apart so had remake it (the rear mount just completely ripped open).

Keep them updates coming!

[JP Racing]

Thanks for the comments lads if all goes well will be at a good few meets and shows this year and back up to scoff for some more power runs

Hey tutuur glad to see the o2m is working well for you. What box code did you go for in the end was it a combo of petrol gearsets and the diesel final drive or just a straight box swap. Now hoping i can get it on the road for march ready for some shows this year so just have to keep on it now.

[w35ty]

Looking good mate cant wait to see it all finished im saving throughout the year now to go vag over this winter.. dont wanna push this jc5 too much! Lol

[Tutuur]

Hi mate,

My box is a hybrid of 3 boxes...
02q jlu final drive (passat tdi)
02m dqb gears (audi tt)
Golf mk4 casing (because of 2wd)

I still have the mk4 gears for ya mate

[JP Racing]

How are you finding the ratios between gears i take it crusing in top gear is at lower rpms than a jb3 or jc5

[Tutuur]

Well tbh theory often seems different than practice, before the 02m i had a jc5-128 (dci 80) and the gears where pretty long but i liked it tbh...

6th gear now is 70mph 2750rpm

[JP Racing]

You also said you ripped the rear engine mount which mounts are you using? Ive gone for the same as turbo ted and run one at the front left as you look at the engine and one at the front right then one at the middle back and a second one on the gearbox passenger side at the back all the v8 landrover ones oh and a kangoo gearbox mount at the top on the strut brace too hopefully hold

[Tutuur]

I only have one at the rear on the original position. I have vibratechnics mounts but the metal piece i made has given in.

I'll upload some pics.

[turbo ted]

hi jon
great to see you got that vw o2m in your engine bay that gearbox mount looks familiar
I modified the rover v8 mounts I cut the studs off and drilled through the mounts and fitted a nut and bolt system through them as them mounts will just pull apart.
mine gearbox is a fqz gears with a drw final drive on the motorway is about the same as Arthur's 2500rpm 6th gear 70mph.
regards rob.

[Tutuur]

Here they are, this is how i had it at first:



With the thick meterial of the tube, reinforced with a diagonal i thought it would have been strong enough but it started to rip open from the bottom just next to the mounting on the engine.

I've now put another tube in the existing tube and made a 3 point which i think will be more than strong enough now:

[Coops]

good progress Mr Jon, looking forward to the 500+ club?

[JP Racing]

Hey coops 500+ are big numbers but we will see what the turbo can do when it goes back to scoffs later this year hopefully wont run out of injectors this tine with 2 sets of 560cc injectors so thats 1120cc in total

[JP Racing]

Well just a little progress to report. The turbo is all bolted up and the down pipe is on to check the clearance is fine. All seems to fit ok. Also put the oil cooler back in place. Should get a little more time on the car later on this week to put the rads and charge cooler pre rad back in. Also need to order a few bits to finish off buy nothing major

[w35ty]

Looking good mate! What you use for hoses ? The samco f7 kit or chop and joiners?

[JP Racing]

Think ive got the black ASH hoses off of ebay and use joiners not the best to look at but i keep them hidden lol also for the coolant i might run the evans waterless coolant to see how that goes it sounds good stuff but quite expensive

[w35ty]

So just straights and bends or the kit like? just wondered as dunno wether to buy the kits and chop where needed or buy diff size hose straights and use joiners.. Also got my c1j samco kit still i can chop and use if needs be

[JP Racing]

To be fair i have custom made rads so just brought straights and bends and cut them to fit my set up. Like i say its not as nice as the kit would be to look at but for me it wouldnt fit for what i needed. If you are running the f7p with std rad then a kit might suit you better as it will look neater if it all fits fine.

[w35ty]

Yeah get what you mean mate :-)

My rads custom just over sized slightly and end tanks slightly bigger but the hose positions are the same still.. Think il get the kits and see what i can chop and make up

[JP Racing]

Got a few interior parts flocked and thinking of having some more done

[JP Racing]

Just a little progress my screamer pipe has been sent away for welding should be done tomorrow night. My strut brace is being modded slightly and should also be done soon too. I also managed to get the car in my double garage to get the drive shafts in. All good until i moved the car and found my drive shaft bolts rub on my down pipe so going to have to take that off and have re done but the other side is fine

[Tutuur]

Keep it going mate, ordered your ND tickets yet?

[JP Racing]

Not yet but I will this weekend

[Tutuur]

[w35ty]

All good mate keep it coming! cant wait to see it all done and on road..

[JP Racing]

Small update again my screamer pipe has been started and will be finished next week just wanted to make sure it fits in place





Also sent my downpipe off to be welded as it needed adjusting and should be back soon

I got round to fitting the clutch cylinder properly and made my clutch pedal up to suit. Once it was done i had a look in my cupboard for spray paint to finish it off and all i could find was a chrome style one it stays for now but will do it black at some time

[B18ftMOJO5]

thats awesome!!

X2. Your engine bay looks epic.

[JP Racing]

Its a bit dusty at the moment but cant wait to finish it again

[Tutuur]

Did you try the clutch installed? What clutch cylinder do you have?

Comparing that pedal to mine you would have way to much leverage

[JP Racing]

I have this set up



Same as scoff this is scoffs pedal too



I have just popped it on but not fully compressed it but if it needs to be less i will redrill and cut the end off

[turbo ted]

hi jon
that mini vertical cylinder might not have enough pressure for your clutch but what rated clutch have you gone for, make sure you fit a clutch stop on the floor other wise you will end up bursting the slave cylinder in the box, I fitted a wildwood 0.75 cylinder regards rob.

[JP Racing]

Hmmm i cant remember to much about the clutch now but i think its an uprated cover and 5 paddle which should be good for around 450ft lbs the mini cylinder bore is 0.70" so not much off the 0.75 size wilwood one you have will look into it though

[JP Racing]

Arr bugger just had a quick read on scoffs thread and the mini cylinder doesnt move enough fluid to disengage the clutch fully d'oh oh well will sort a new one out

[Tutuur]

Robbie didn't you have a mini cylinder too?

Regarding the .75 master, scoff and Robbie told me to get that one, when fitted even with smaller leverage it was a pig to disengage. I've now fitted the smallest wilwood master (somewhere in the 60ies iirc) and shortened the leverage and now it's good....