Rob + Kelz Black Mk1 Leon Cupra 4WD Quattro Project

Aug 27, 2012
581
0
Maidstone, Kent
Sounds good at the moment mate not to loud misses seems ok with it at the mo does give a nice sound in boost too, pretty quiet and subtle on idle and usual driving(the misses driving) lol
 
Aug 27, 2012
581
0
Maidstone, Kent
So washed the car yesterday and the pressure washer took my S badge off the SEAT!

So I decided to de-badge it today!
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Also a quick shot of the new exhaust now it's off the floor and on the ramps
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Random side angle shots
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And some cheeky pictures of the engine bay, now deciding what to do to the bay... Thinking maybe some silicone coolant hoses to match the rest of the blue?
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Aug 27, 2012
581
0
Maidstone, Kent
Well decided this is pretty much as far as I'm gonna go with engine mods for now so the car is now booked in for a stage 2 remap next month so in the meantime I'm just gonna tidy it up and make some minor changes to bits and pieces

Give it a service etc :)
 
Aug 27, 2012
581
0
Maidstone, Kent
Some goodies on the way, I've ordered some decent vacuum caps for the bottom ports on my inlet rather than the bits of pipes with bolts to plug the holes lol

Some JCS hi-grip clamps for all my boost pipes as some of my clamps are pretty useless even tho none have popped off

An intercooler bead roller as none of my pipes are currently rolled or flared so going to flare them this weekend

Radiator has a slight leak I think so ordered a new one to fit this weekend

Taking my bumper back off and going to have another look at fitting the intercooler better and a bit more consistent with the drivers side route, looking to go up behind the passenger headlight and then over the gearbox area onto the turbo outlet

Also booked in next week for a coolant, thermostat, water pump and Cambelt change and a service the following week

Then off on the 6th-7th for a stage 2 remap :)
 
May 18, 2013
190
0
is your passenger headlight going to fit in with that pipe running where it is....looks very tight
 
Aug 27, 2012
581
0
Maidstone, Kent
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Aug 27, 2012
581
0
Maidstone, Kent
My package turned up from Awesome GTI :)
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All my items for the water pump + cambelt change, also thermostat, thermostat housing idler tensioner etc
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Also fitted my oil catch can

Now all ready for my remap on Friday :funk:
 
Aug 27, 2012
581
0
Maidstone, Kent
Well I changed my oil pickup pipe, cleaned sump refitted that, changed oil filter, fresh oil and new plugs

Then traveled up north to the hotel last night and then had my car remapped to stage 2 plus launch control this morning :) drive home was excellent!!
 
Aug 27, 2012
581
0
Maidstone, Kent
Like a different car mate, just so smooth and responsive and pulls like a train through all gears lol and only mapped to about 20psi rather than 22/24 like some lol

He said it responded extremely well especially in the hot weather as it was baking got up that way Friday lol

I still got one intercooler pipe yet to change which comes out the turbo and joins my pipework its from the standard one I cut it so that it still had the ports on it but its 2" where my pipework is 2.5"

I got the new one for it all cut and ready just need the DV and N75 port welded on and then I can fit it, may not even make any difference but you never know lol now debating to get WMI or not
 

thehawk18

Active Member
Nov 26, 2010
395
0
Lincoln
Very nice car pal! Just had a quick browse and looks very tidy. Looks almost sleeper-esque from the outside yet theres a lot under the bonnet.
 
Aug 27, 2012
581
0
Maidstone, Kent
Thanks :)

Yeah I was debating to go down the sleeper route, spray the cooler black and get black 45deg bends that I use from the cooler and then leave all under the bonnet stuff like it is now

But still I cannot have my fogs :( I'm going to look into a few ways that I could still have the fogs then I'd be even happier as it will look even more stock lol

Does anyone know if fogs on LC and LCR bumpers are in the same location?
 
Aug 27, 2012
581
0
Maidstone, Kent
Ok so after an eventful ending to April the gearbox decided to go bang on the Leon and the clutch is shafted!

So I started removing the gearbox the weekend before last (26th April) and thought I'd take a peek inside...

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And lastly, the clutch! Or at least what is left of it...

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So my decision at this point was what to do next... I've always wanted to do the 4WD conversion on my Leon with the quattro/haldex rear etc! So that was my choice, on Friday evening last week I went to pick up an Audi A3 1.8t Quattro and then Saturday I started removing the front end and the gearbox, engine etc and then started to put the gearbox on my Leon

The transfer box was a pain as it was hitting the back of the engine when trying to get the gearbox into place, in the end I dropped the subframe so I could lift it up into place a lot easier, it was still a nightmare to get into place but none the less we got the gearbox in!

Sunday morning I started finishing off bits and pieces, putting the rest of the bolts in the gearbox and tightening them up and putting the starter motor back on etc, got the passenger driveshaft back in and the leg on all bolted p and back on its wheel that side

Now the fun began! On the drivers side obviously I needed to use the A3 quattro driveshaft as it is shorter due to the transfer box... But turns out the oil return line from the bottom of the turbo to the sump is in a different position on the Quattro, it's a longer pipe and goes towards the side of the engine before round to the turbo! So my original line was right in the way of putting the driveshaft on! I had the oil line I needed as I had the engine off the A3 still, but it was a complete pain in the ass to get the line off as it was very tight between the bottom of the turbo and the transfer box. Had I known about this before putting the gearbox on it would of been a 2 minute job

Anyway I got the old one off but struggled like hell! So I decided to drop off the transfer box to put the new one on, got that all tightened up and on and then the transfer box was back on and the car was good to go again! (After bleeding the clutch obviously)

Then I had oil dripping like mad :( so I thought I hadn't tightened up the oil line properly or something as it was dripping when it was running but I couldn't get to it to check it was tight etc, so I ordered a new gasket and 2 new bolts for the oil return line... Then got at it lastnight and dropped the transfer box back off and then removed the line and put the new bolts and gasket on and sealed it all up

I now know why it was leaking!! The bolts I had put in were wrong, well one of them was. I had one bolt longer than the other and the long one was obviously hitting the end of the hole/thread before tighening the oil line to the turbo! But anyway this is all done now and part 1 of my 4WD conversion is complete, it now has the 4WD gearbox and transfer box.

The Leon is now usable for time being, I'm giving myself a couple of weeks to get the A3 stripped down of all parts so that I can start drilling the spot welds out and cutting the floor out ready for it all to go on to the Leon :)
 
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Aug 27, 2012
581
0
Maidstone, Kent
Done some more work on stripping the Audi down this weekend, spent most of Saturday moving everything out of the car into the garage all I need to do now is remove the bolts holding the rear subframe to the car and then drop that off the car

Was hoping to have had that done yesterday but after breaking three of my ratchets and having no more to use I had to tidy up and call it a day, a new ratchet is on its way tho!

Once the rear subframe etc is all off I shall give it a clean up and either have it powder coated or give it a going over with hammerite

I will also be getting a full powerflex bush kit for it all too so it will be nice and fresh along with some adjustable tie bars and a set of coilovers
 
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