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Author Subject: Project PUG
chris with a pug

Seasoned Pro

Location: Southampton

Registered: 16 Feb 2003

Posts: 5,366

Status: Offline

Post #1
Well I think its time to show you lot what I have been doing to my 6.

A bit of history of the car, I have owned it since 2003 and she has been great to me, no major problems apart from the clutch.

I got a 6 month ban 2 years ago for reaching 12 points, so I took it off the road, since then I not really used her much.

I then met rich_w on here and decided it would be a good idea to super charge it and get her back on the road.

So i started to remove the engine



so much easier to take out with the slam panel off.




The engine is now stripped to the block and all the parts are in boxes, and just waiting to get the pistons so I can get the boring doen and get it back together.


The crank went to longmans as you all know and I got the bearings and stuff I need.




So today I spent the morinig striping the engine bay ready to be sprayed so all the pipes clips and everything now in a box.





Some of the nuts on the brake lines would not budge so I had to cut them (one the goes to the master cylinder and one that goes to the back calipers).
Also removed all the capliers to get them referbed, sending them to big red, I did find that one of the rear pipes is a none standard one and was make of copper so just twisted and snapped, does anyone know what the pug ones are made of and is it best to get them from there.

I got most of the parts I need to supercharge it not, apart from the pistons as I mentioned earlier and the charger its self.

not sure if this will make a differance but hey i brought it now.





oil cooler

intercooler


so thats pretty much the engine covered, so to the body work.

About 4 years ago some little shit, decided to try and break into my car, he got as far as ripping the lock out the drivers side door, then left it, anyway, I decided to delock the car as this would be cheaper and i always liked delocked cars so my uncle welded up the holes and they wuer smoothed.

This year I then decided I liked the cmoothed look so all the bump strips got removed, as well as side repeaters, i am leaving the boot as it is as I dont like thre look of smoothed boots.


smoothed wings

smoothed rear quarters

smoothed bonnet.

this weekend I am hoping to seam weld my sub frame (after talking to daveyboy seems like a good idea) and get my mount welded


so this is my project so far, in the near future might hold a meet at my house so you can all come help me put it back togehter as I migh forget where it all goes

Posted 13th Nov 2007 at 19:28
cress87

Seasoned Pro

Location: Norwich

Registered: 30 Mar 2007

Posts: 11,360

Status: Offline

Post #2
Nice work! Cool Looks like it's coming on nicely. Thumbs up

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Posted 13th Nov 2007 at 19:41
rallyestyle

Seasoned Pro

Location: London

Registered: 23 Jul 2003

Posts: 14,989

Status: Offline

Post #3
Take it you thought about the crucial mathematical formula needed for this to succeed?

Driving Ban + Modified Supercharged GTI6 + Gaylord Insurance Broker = Instant Bankruptcy Sad

Unless preceded by

Lottery Ticket + Rollover Weekend + Extreme praying to the skies = Stinking Rich Smile

Im sure it will be worth it though fella Wink

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Posted 13th Nov 2007 at 19:49
mnpr4

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Location: NW London

Registered: 29 Jan 2007

Posts: 1,195

Status: Offline

Post #4
Good stuff mate. Thats alot of hard work. Hope you get her back together and charged Devil

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Posted 13th Nov 2007 at 19:51
willygti

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Location: Exeter

Registered: 08 Oct 2007

Posts: 5,024

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Post #5
Ahh what.. no lexarse lights Whistle

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Posted 13th Nov 2007 at 19:52
chris with a pug

Seasoned Pro

Location: Southampton

Registered: 16 Feb 2003

Posts: 5,366

Status: Offline

Post #6
I am dreading the insurance when it comes up, my no claims has run out to, but hey its not like I cant afford it well unless its more than a few grand, whcih i cant see it being that much
Posted 13th Nov 2007 at 19:53
chris with a pug

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Location: Southampton

Registered: 16 Feb 2003

Posts: 5,366

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Post #7
willygti wrote:
Ahh what.. no lexarse lights Whistle


why would it have them?
Posted 13th Nov 2007 at 19:53
willygti

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Location: Exeter

Registered: 08 Oct 2007

Posts: 5,024

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Post #8
chris with a pug wrote:
willygti wrote:
Ahh what.. no lexarse lights Whistle


why would it have them?


Just ignore me lol.

No in all seriousness how much is this going to cost in total from standard 6 to sc'd?

Love

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Posted 13th Nov 2007 at 19:55
forest1981

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Location: Lincoln

Registered: 02 Dec 2005

Posts: 7,982

Status: Offline

Post #9
awesome Cool wish i had the time and the money to have a project like this

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Posted 13th Nov 2007 at 19:57
chris with a pug

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Location: Southampton

Registered: 16 Feb 2003

Posts: 5,366

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Post #10
good question, I not really added it all up, but here goes

Supercharger kit 1000
fly wheel 180
Alloy crank pully 100
intercooler 150
oil cooler 140
fuel lines and nuts 20
recon brakes 200
disks and pads 200 estimate
misc 500 ( gaskets nuts bearing etc)
fuel pump will be 100
and swirl pot when rich makes them no idea
roller bearings 200
aux pully was 30
supercharger will be 1000 ish
pistons about a 1000 too
Posted 13th Nov 2007 at 19:59
nashy

Sarcastic Tw@

Location: Nuts deep

Registered: 13 Aug 2004

Posts: 14,788

Status: Offline

Post #11
^ Thats pushing 5k already! Ouchy! Hope the insurance doesnt sting you too much when you get it all put together.

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Posted 13th Nov 2007 at 20:09
chris with a pug

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Location: Southampton

Registered: 16 Feb 2003

Posts: 5,366

Status: Offline

Post #12
thats complete though and to be fair where can you get close to 400 bhp for 5k? am hoping to get it sprayed as well and all toghether for 5k.
Posted 13th Nov 2007 at 20:11
rallyestyle

Seasoned Pro

Location: London

Registered: 23 Jul 2003

Posts: 14,989

Status: Offline

Post #13
chris with a pug wrote:
good question, I not really added it all up, but here goes

Supercharger kit 1000
fly wheel 180
Alloy crank pully 100
intercooler 150
oil cooler 140
fuel lines and nuts 20
recon brakes 200
disks and pads 200 estimate
misc 500 ( gaskets nuts bearing etc)
fuel pump will be 100
and swirl pot when rich makes them no idea
roller bearings 200
aux pully was 30
supercharger will be 1000 ish
pistons about a 1000 too


Don't forget your LSD buddy, think it will be coming in handy Thumbs up

Will be great to see it once its finished Smile

________________________________________

Just Drive It
Posted 13th Nov 2007 at 20:20
phillipm

Seasoned Pro

Location: Rotherham

Registered: 15 Oct 2006

Posts: 20,601

Status: Offline

Post #14
quote:
this weekend I am hoping to seam weld my sub frame (after talking to daveyboy seems like a good idea) and get my mount welded


Justmake sure you use weld through primer beforehand. Thumbs up

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Posted 13th Nov 2007 at 20:20
jim01uk

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Location: around

Registered: 16 Dec 2005

Posts: 8,996

Status: Offline

Post #15
might have been an idea to do insurance quotes before starting the project? Although I suppose you can get the engine built and ready, but if they wont insure you on it for a while just drop a standard lump back in for a year!

love looking at projects, wish I had the patience to do something like this - But I'm lazy and dont like being cold or dirty Erm? so its out of the question really! LOL
Posted 13th Nov 2007 at 20:29
anth

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Location: Colchester

Registered: 04 Apr 2006

Posts: 3,650

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Post #16
quote:
the bump strips got removed, as well as side repeaters


Is that legal?

Posted 13th Nov 2007 at 20:32
russbez

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Location: Inverness-Shire

Registered: 19 Dec 2005

Posts: 7,456

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Post #17
will be watching this thread Yes

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Posted 13th Nov 2007 at 20:35
jim01uk

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Location: around

Registered: 16 Dec 2005

Posts: 8,996

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Post #18
MOT tester may decide that the front indicator can be seen from the side and it will therefore count as a side repeater too iirc
Posted 13th Nov 2007 at 20:38
anth

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Location: Colchester

Registered: 04 Apr 2006

Posts: 3,650

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Post #19
jim01uk wrote:
MOT tester may decide that the front indicator can be seen from the side and it will therefore count as a side repeater too iirc


so you could be open to rape in other words?
Posted 13th Nov 2007 at 20:44
willygti

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Location: Exeter

Registered: 08 Oct 2007

Posts: 5,024

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Post #20
nashy wrote:
^ Thats pushing 5k already! Ouchy! Hope the insurance doesnt sting you too much when you get it all put together.


Or just don't declare it:

"so is your car modified in anyway sir?"

"nope, all standard mateWhistle"

LOL

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2003 Subaru Impreza STi
Posted 13th Nov 2007 at 20:52
barry.rs

Seasoned Pro

Location: South West

Registered: 03 Apr 2003

Posts: 7,389

Status: Offline

Post #21
anth wrote:
jim01uk wrote:
MOT tester may decide that the front indicator can be seen from the side and it will therefore count as a side repeater too iirc


so you could be open to rape in other words?



IIRC its not a legal requirement as a lot of older cars donít have them fitted but if they are fitted they must work.

Posted 13th Nov 2007 at 20:56
puglover Banned!

Location: Far out there

Registered: 08 Jun 2006

Posts: 6,096

Status: Offline

Post #22
yeah you might wanna get that mount looked at Shock mine was still sweet just some surface rust that ive now taken care off. will be giving it some waxoyl too to prevent things abit futher. looking good though
Posted 13th Nov 2007 at 20:59
petegti6

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Location: Solihull & Market Harborough

Registered: 09 May 2006

Posts: 12,046

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Post #23
Looking good, i'd like to see some progress from the other members of the charger club! Smile

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Posted 13th Nov 2007 at 21:09
CUJ

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Location: Southampton

Registered: 18 Apr 2006

Posts: 22,218

Status: Offline

Post #24
Good work mate, interesting stuff. Keep us updated Thumbs up

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Posted 13th Nov 2007 at 21:14
rallyestyle

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Location: London

Registered: 23 Jul 2003

Posts: 14,989

Status: Offline

Post #25
willygti wrote:
nashy wrote:
^ Thats pushing 5k already! Ouchy! Hope the insurance doesnt sting you too much when you get it all put together.


Or just don't declare it:

"so is your car modified in anyway sir?"

"nope, all standard mateWhistle"

LOL


Sad Angry You best be kidding Guns Whistle

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Just Drive It
Posted 13th Nov 2007 at 21:38

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