Owner, jonathan reeve
Location, nr norwich,uk
Model, vw rallye golf se
Extras, abs,power steering,electric windows/heated+electric mirrors/ electric sunroof, sem manifold, omp lower strut brace
Estimated bhp, 289bhp 302lbft
Brakes, porsche 4pots
g/box drivetrain, 02c
Bodywork, debadged grill
Future plans, 550bhp+nos and haldex
sum people will know the car better than i do
this is what the rallye replaced.
and the rallye
still looking good!
got this to help it along
gt3076r hta with tial v-band housing
vibratechnic comp mounts
valve train kit
ina baffled sump
i have loads of engine parts in boxes with so much left to buy
right, lost 2nd and reverse so the haldex conversion is now on.
this meant getting the rallye converted axle of my shed. already bought one about year ago but hadnt bothered to start it yet.
me and a friend got the rear arms stripped of bushes and bearings ready for painting.
now the fun begins, i bought 4xvr6 cv’s joints, 2x rallye 68mm bearings, drilled rallye rear discs, 4x vr6 front hubs and 2x new abs rings.
bought sum rallye driveshafts but they turned out to be syncro ones, but luck has the rears are same as rallye and thats what i needed.
right the machining. friends neighbour is an engineer and works from home so this little lot cost me £45.
what im using:-
tt inner rear cv’s
cv’s need bit machining down to fit abs ring
rear shafts need 2.5mm off both ends on both shafts.
rallye rear shafts are :404mm long, 390mm circlip to circlip and 544mm long, 530mm circlip to circlip
after 2.5 off either end they should be 399mm and 539mm in total length
shud now be 31mm for tt cv(same as tt cv)
inner cv needs 5mm machined to allow tt inner to slide further on with washer.
as for rear hubs i have used mk3 vr6 front hubs which require slight modifying.
2mm on overall size of hub as rallye discs didnt fit.
also on the back is sum steps. one step needs machining down.
i already had bought sum drilled/grooved rear rallye discs but there 4 stud and i want 5 stud. so they’re been redrilled.
worth mentioning this a 5stud setup!!…….
this should be the rear setup done.
Looking great, jof !
hopeing to see more pics of your conversion.
picked up clutch today after waiting 6weeks.
clutchmasters cm725 twin disc.
shud be good for full throttle 2nd gear launches 😆
engine is out but forgot to take pics…oops!
well ive made a start…..
had a right job getting hub nut undone. 15mins with alot heat finally did it after i broker a big breaker bar 😆
took me about an hour to do, never had this problem before. forgot the socket was hot and picked it up. now have ring burned in my hand 😆
removing rear mount from subframe to allow cv clearance
new clutch fitted with new oem flywheel bolts
had to remove balance weight from subframe as gearbox rests on it and remove my lower strutbrace.
engine back in with the 02m 6sp box fitted
just need to weld mount back on subframe when i check clearance of cv with rear mount and power steering pipes
worth noting you need to have a bracket made to fit the vw front mount to stop it twisting. i’ll put pic up off one i had made.
i had new vr6 front wheel bearings and vr6 front hubs fitted to my rallye hub carriers.
also had my 305mm discs redrilled to 5×100 and had the disc retaining screw tapped back in.
this lot cost £46 to have done. i have a bearing press but couldnt be bothered to do it myself 😆
the rallye abs rings need to be fitted to the vr6 hubs as the vr6 abs rings are a different offset.
when fitting the rallye abs rings to vr6 hubs sum machining is needed to abs ring to make space for the wheel bolts.
just got to fit my new stone guards to the hubs now and job done.
currently have my new wheels welded and redrilled by voodoo motorsport.
today got the hubs refitted with new tack rod ends and bottom ball joints. also managed to get the shifter fitted for the 02m box. i used the polo shifter housing and it bolt straight in. just had to cut the bottom plate a little because i fitted a b&m short shift lever and its longer so the cable touches the bottom plate.
also did sum measuring for the driveshafts.
was looking at the measurements on syncro site and i measured slightly
longer, but because the inner cv can move in and out a inch each way i
think there is quite alot of room for error.
i measured 320mm drivers side( mines lhd)
passenger side 416mm
i measured flange to flange.
so for total length its 320mm + 36mm (splined bit for inner cv) + 48mm (splined bit for outer cv) total = 404mm
so for total length its 416mm + 36mm (splined bit for inner cv) + 48mm (splined bit for outer cv) total = 500mm
ive also made an error as i was going to use vr6 front cv;s but these dont fit on the tt shafts so going to use the tt inner and outer cv joints.
I did finish the Haldex conversion, used car for couple of months then was dismantled
Car is currently just a shell
Why dismantle it after all the hard work?