After YEARS of Work… Turbo R32 Finally Looks Like a Car Again

0:00 Today we're back with our turbo Mark 4 R32

0:03 and we have a ton of things that have to happen.

0:06 This may not seem like a huge deal,

0:08 but my goal by the end of this video is to get this car on the ground.

0:12 Up until this point in our build, time has not really been a problem.

0:16 However, our clock is ticking.

0:18 We have only a few weeks before this car needs to be fully done, running,

0:22 driving, and complete so that we can bring

0:24 it to this year's Wookies in the Woods.

0:32 Gross.

0:33 So, these are the axles that were in the car that have been out for many,

0:37 many years and you can look at just look

0:38 at how gross look at how gross this grease is.

0:41 I don't suspect that's going to be

0:43 doing a whole lot of good quality lubrication,

0:45 so we're going to rehab all four of our axles.

0:49 This is the back driver side one and it might be one of the worst ones.

0:53 So, we're going to refresh.

0:54 We're going to refresh the axle shaft.

0:56 We're going to put new boots on it.

0:57 We're going to clean all the stuff out, new grease, clean our balls.

1:00 We'll be fresh.

1:01 This is a place where initially I was like, you know what?

1:04 We're just going to get driveshaft shop to make us some new custom axles.

1:07 Something to support the 500 wheel horsepower

1:10 that we're shooting for, but in talking to them,

1:12 they're like, hey, those axles will hold the power, no problem.

1:14 So, this is not a hard job.

1:16 The only bad part about it is it's gross.

1:18 In what world is that going to do a good job for our axles?

1:22 No bueno.

1:22 This car had 200k on it.

1:24 It's reasonable to assume that at some point it had some axle boot replacement.

1:29 This paint or coating, whatever, should go all the way across,

1:33 but one little chip in the paint,

1:35 some water in it, and your axle will be rusting.

1:45 Yeah, but even this like that compared to what

1:48 the inner joint was is night and day.

1:50 Our goal is to get as much {slash} all of this grease out.

1:54 Also done something cool.

1:56 It's on the printer right now.

1:57 I 3D printed a little stand, so we can stand our axles up,

2:00 fill it with like mineral spirits

2:01 or something a little more aggressive than degreaser, and let that soak in.

2:05 For now, we'll put our outer joint on.

2:08 We'll just run it like this, flip it in a little while.

2:10 30-minute timer.

2:11 We'll probably run this like a bunch times.

2:15 This is our front driver side axle.

2:18 And as you can see, it's not nearly as bad and yucked up as our rear ones are,

2:22 but fair to assume that the grease is probably the same.

2:24 So, we're still going to reboot, regrease, and I'll throw a little coat of paint

2:28 on this one just so it looks a little nicer.

2:30 This one I I wanted to test drive the method to getting it rehabbed,

2:34 so I did this one first.

2:35 And look, I think it looks great compared to what it was.

2:38 Is it perfect?

2:39 No.

2:39 Is that a problem for me?

2:41 No.

2:41 The grease is good, so I think it's going to be just fine.

2:48 All right, I think we did a pretty good job.

2:50 What I'll do next is I will paint this, and then

2:54 after that dries and cures for like a day, we'll do some of the epoxy paint.

2:59 And that will not only get our axle looking 100 times better,

3:02 it'll do a good job protecting it, too.

3:04 So, two more axles after this, but the front ones aren't too bad.

3:07 So, this is like as bad as it gets here.

3:10 Just beyond the door is a mess.

3:12 In here, it's not horrible, but I will say we put a lot of parts on the R32,

3:17 so that gets things off the bench,

3:19 but speaking of parts on the R32, look what came today.

3:26 So, we already have an I bad oil filter housing on the car,

3:30 but the one we have doesn't have any provision really for an oil cooler.

3:34 This is an updated design since I got this one like 100 years ago.

3:37 Normally, all this is covered up, right?

3:39 You have your radiator, you have your condenser, you have your fans.

3:42 The radiator is only for coolant, but right in front of the radiator is

3:45 a small bracket that acts as a power steering cooler.

3:48 On the US cars, we have an auxiliary radiator here on the passenger side.

3:53 And apparently, the European cars don't have this.

3:56 So, what I'm thinking as of right now

3:58 is we're going to probably not use the radiator,

4:02 but we're still going to put a small radiator in this location.

4:07 And it's going to be a dual chamber Again, I'm still like working through this.

4:11 So, if you're like, "Charles,

4:11 that's really stupid." Please tell me in the comments,

4:14 cuz I might be way off base on this.

4:16 This is just what I'm thinking like as of right now.

4:18 We do a dual fluid radiator heat exchanger.

4:22 We run our oil cooler to it, and we run our power steering lines to it.

4:27 So, it'll cool oil, it'll cool power steering.

4:29 We can put a fan on the backside just to do

4:32 as good of a job cooling our oil as we possibly can.

4:35 But, what I really want to show you is this.

4:36 So, this is the factory oil filter housing, right?

4:38 We have a cartridge that goes in here.

4:40 You have your oil pressure sensor right here.

4:42 This is the actual cooler itself that a small bit of coolant runs through.

4:47 Adding essentially double the horsepower,

4:49 adding all the heat from a turbocharger, we have to be mindful of oil cooling,

4:55 coolant cooling, and power steering cooling is actually one

4:58 that a lot of people struggle with at Wookies.

5:00 I think that might be like the most common

5:02 thing that people have issues with is power steering circuit.

5:05 So, you're in a high-performance driving situation.

5:08 I don't think that little bracket at the front

5:09 of the radiator does all that much.

5:12 With all that stress on the rack,

5:14 with all that stress on the pump, it boils the fluid.

5:17 As it gets old, generally anyway with fluid,

5:20 the boiling point will come down, which is what you don't want.

5:23 With this housing, we have the same screw-on filter here.

5:26 This is oil fittings, and then we have a couple of extra ports,

5:30 one for the factory oil pressure switch.

5:32 We have an 1/8 NPT, I think, takeoff,

5:35 so we can run an aftermarket oil pressure gauge if we wanted.

5:38 Then we have one more fitting that if we want to run our oil

5:42 feed line to our turbo from here up to the turbo, we can do that.

5:45 So, really, have a piece like that and then you could

5:49 still screw the oil filter on down here at the bottom.

5:51 Kind of like the older 1.8 turbos,

5:54 kind of like the older 2 liters, like the ABA's, the AEG's.

6:00 That's how they run.

6:01 A lot of these kind of things,

6:02 these very specific, will this be better than that?

6:05 I don't know.

6:06 You go on the internet and do research,

6:07 you're going to find one group of people that says this is

6:09 the greatest thing ever and then the other group's going to say,

6:12 "That's the stupidest thing ever." They both can't be right.

6:16 Let's just put the part on.

6:17 Oh, here's a thing that I have a question for you guys on.

6:20 We made a little short showing like filling the oil filter, putting it on.

6:24 The cool thing about the VR's, you can prime the oil system, right?

6:27 And I we made this little reel about it and I was like,

6:29 "This is cool, I think, anyway,

6:31 and maybe valuable information." And a ton of people are like,

6:34 "That's the worst thing you could ever do to an engine.

6:37 Never pre-fill an oil filter.

6:40 Priming the oil system, lol." Well,

6:44 so I do it because look at one, how enormous this oil filter is.

6:48 And if you don't pre-fill this, that's a lot

6:50 of time where there's no oil in the filter,

6:52 which means there's no oil downstream as well.

6:55 And two, do you really want to start the car without the system primed?

7:00 Like on a brand new rebuild?

7:01 If you don't do that, your your engine

7:04 is running or you're cranking it while that's happening.

7:07 To me, that seems silly if you don't have to do it that way to do it that way.

7:11 But, a ton of people were like, "Oh, that's the worst thing you could do

7:14 for your engine." If I'm going to ruin the engine, all right, here's the deal.

7:18 If this engine blows up right away after it starts,

7:21 you know this is the moment that led to that.

7:24 It's this right here.

7:26 And then I haven't decided if we're going

7:27 to do an oil pressure gauge or not and I

7:30 haven't decided if we're going to run the oil

7:32 feed line to the turbo up around and back.

7:34 It's a long road, but I think it'll be good.

7:38 In the video where we put the Touareg 18Z brakes on the R32,

7:42 we all, me included, had a ton of questions.

7:45 And the main one was, is the master cylinder from the car going to be enough

7:49 or appropriate is probably more accurate to drive the bigger brakes.

7:54 We went from two pistons in the front, each side, one piston in the rear,

8:00 each side, to six in the front and two four in the back.

8:04 So, we really upgraded the brakes.

8:05 Now, a ton of people run 18Zs and Touareg rears

8:08 and don't have any problems on factory R32 master cylinder.

8:12 Plenty of people also say the pedal feel is terrible.

8:15 So, the guys at Eiptec make a kit that has an adapter bracket.

8:19 This is a right-hand drive Touareg master cylinder.

8:24 So, there is one thing I'm noticing.

8:26 On the R32, we have this pressure sensor thing right here.

8:29 We don't have a prov- Oh god,

8:31 look at how gross that brake fluid was, by the way.

8:33 The Touareg one does not have a provision for that.

8:36 So, is that going to be a problem?

8:39 I don't know yet.

8:40 So, we're going to run it and see.

8:41 Now, I said we were going to initially run with just the factory one first.

8:46 We're still going to do that.

8:47 I just have a little bit different plan for it.

8:48 So, let's move to the car and get this put on and see how it goes.

8:52 Probably sticks out a little bit further than the stock one does,

8:55 but it's not too bad.

8:56 But, this is all going to be about proper movement

9:00 of the pedal and then the pistons in each of the calipers.

9:04 This might actually provide a little bit better brake pedal feel,

9:08 too, because we reinforced the master cylinder against the booster.

9:12 This is an area I'm not 100% sure.

9:14 So, VW and Audi often times use brake fluid as the fluid for the clutch.

9:19 So, if you look at this reservoir, you see this little nerple right here.

9:22 Well, and if you look at this reservoir,

9:25 it's got a similar nerple, but it's blocked off.

9:29 All you have to do is just cut that and then it's not blocked off anymore.

9:40 Ooh, I don't like that at all.

9:42 Uh all right, here's what I'm thinking.

9:43 I think I'm going to get a little bit longer line.

9:46 What's happening is this plate is bringing all

9:49 this out forward cuz this would normally live like here.

9:52 And there shouldn't be much flex in all this stuff.

9:55 Let's leave it for now.

9:56 I'll shop around and see if I got one.

9:58 These are not in the most primo shape,

10:01 but I think they're going to be good enough.

10:03 I'll clean the threads, clean this bottom part out.

10:06 You can see there's a little bit of yuck right there.

10:08 Coolio.

10:08 Let's put this one in first.

10:15 I think this one we have a better chance just cuz it's a longer line

10:19 and we have more spots where we can just kind of flatten these bends out a bit.

10:23 But this one, this one's pretty far.

10:26 The next part of our journey is a journey of test fitment

10:31 and probably a lot of trial and error and that's dealing with our wiring.

10:34 On the floor here, I have three four wiring harnesses that we have to deal with.

10:41 So this harness is the harness that is my spare R32 engine side harness.

10:47 This harness is the one that was in the car when we took it apart.

10:52 And then this one is the body side engine.

10:55 So all these connectors go into the inside of the car.

10:59 This is the big boy connector and then we have like our starter stuff.

11:03 And then on this side is our oxygen sensor stuff.

11:06 So we need this.

11:07 This harness, my spare one,

11:08 seems to be in a little bit better condition except for this.

11:11 This is someone cut the speed sensor.

11:13 We're not actually going to be doing a lot of wiring in the sense

11:17 of depinning and repinning and moving wires

11:20 around like when you do an engine swap.

11:21 Really, the only actual like wiring wiring we're doing is

11:25 we need to replace these injector connectors with those little pigtails.

11:29 So I'm going to take these two harnesses and then

11:32 the harness that's still in the car and we're just

11:33 going to start laying some of these out knowing that we're

11:36 going to pull this all back out to rehab it.

11:39 So, this is the alternator harness.

11:41 It has the connection for the alternator charging excite wire, AC compressor.

11:47 This harness is a problem almost on every Mark IV.

11:52 They get hot, they melt the fuse panel on the battery,

11:55 and then you have sad harness, sad battery, and possibly sad alternator.

11:59 The great thing about these harnesses that are very

12:02 problematic in just about every Mark IV is that you

12:04 can't get them anymore because Volkswagen hates all of us

12:08 and they think we should just buy new cars.

12:10 That's why they have the drivers wanted campaign cuz they want you

12:12 to drive any cool car they make as long as it's a silver SUV.

12:16 But, here's a good thing, right?

12:17 This is a good thing about most of these things

12:19 that I complain that VW doesn't support anymore.

12:21 The One, you could make this harness very easily, right?

12:24 If you have the tools to crimp and splice wires, you can make this super simple.

12:28 But, if you don't or you don't want to, our man Clusters by Litkey

12:32 makes these harnesses either just the alternator or he sells the whole thing.

12:36 If you need one, Clusters by Litkey is the place.

12:38 He's our man that also does our cluster repair

12:41 and a bunch of other stuff and just a cool dude.

12:45 Let's check on our axles here.

12:49 Yeah, this water was fresh and clean when we started.

12:53 So, it looks like our inner joint came apart, but at least the Cool.

12:59 My balls.

13:00 We're going to take this out of there, wipe it off,

13:03 and I'm going to stack it in that holder that I made.

13:05 The sole purpose of this device.

13:07 Then, we're going to just pour something

13:10 a little more aggressive in, let this soak.

13:13 That should hopefully thin that grease out real good.

13:16 This cover for the AC line, unfortunately,

13:19 as I was cleaning it really started to come apart.

13:21 So, I figured I would just take the rest of it off and we'll re-wrap it.

13:25 The HPA kit comes with a heat shield anyway,

13:27 so it's going to be like double covered up.

13:29 I still wanted to make it look decent.

13:31 Gosh, it everything looks so nice until I

13:34 puked all the wires out across our engine bay.

13:37 This is the rough layout of where our wires are going to go, right?

13:40 This stuff tucked into the cowl and then I have to do

13:43 something with this because our new intake manifold doesn't have the channel.

13:47 We're either going to re-wrap this, maybe we'll use this kind of tubing.

13:51 I do have new red connector ends, but we really need to be starting to think

13:56 about all the pieces of the puzzle, right?

13:58 Yes, we have the engine in.

14:00 Great, cool.

14:01 The brakes are pieces are in.

14:03 Great, cool.

14:04 But, what I don't want to do is I don't want to go all the wiring

14:07 and then have take a bunch of wiring back off because of our coolant hoses.

14:11 It can be a bit hectic because you got

14:12 to put this wire on, but then this coolant hose,

14:14 but then what do you do with your oil cooler?

14:16 Despite the last video where I took a lot of things off and redid them,

14:19 this is where we're going to be staging a lot of things,

14:22 taking it back off, staging it, taking it back off,

14:25 all to build for a very easy final assembly.

14:28 But, if you remember what we did with the yellow car after the RS3 swap,

14:32 we did our big test drive shakedown on Tail of the Dragon.

14:36 I do not want to do that with this car

14:37 because every single bolt on this car has been touched.

14:41 Engine's rebuilt.

14:42 We got the rear limited slip Haldex.

14:44 I want a lot of time to do some good shakedowns,

14:47 be a little more spirited with it,

14:49 and make sure that when we drive this car to Fontana,

14:51 we don't have a breakdown in the mountains.

14:53 Oh, did I tell you guys we got the exhaust?

14:55 I don't know that I did.

14:56 We got our exhaust.

14:57 We have a full Milltek high flow cat,

15:00 so basically downpipe back with our freshy Milltek tippys.

15:06 This is their V2, so this is the same exhaust I have on my red R32.

15:09 Let's do a quick rundown of all the things we have left to do, right?

15:12 Torque everything in the rear suspension,

15:14 finish our axle rehab, swap the power steering lines,

15:17 get our oil cooler sorted, shifter stuff sorted, our coolant lines,

15:22 our full interior, radiator, core support, condenser, receiver dryer.

15:26 I have all those parts.

15:28 A lot of this project has been we got a ton of stuff to do,

15:31 monumental moments, right?

15:32 Our engine's in, our rear suspension is in, our brakes are on.

15:35 This is great, this is cool.

15:36 Now is really where little tiny details are going to need to be accounted for.

15:41 And even though this car ran and drive before we did any

15:44 of this, it's very likely that something has happened in the time frame.

15:48 But, look, huge moment.

15:50 Okay, after some coats of paint and some cure time,

15:54 I would say this came out about a six out of 10, which is fine.

15:59 Listen, they're axles.

16:01 This is not a car that's going to be trailered everywhere.

16:03 This is going to car that's going to be driven.

16:05 I will say like, look, doing axles, this stuff is not hard.

16:08 This always take a special like hold your mouth right kind of situation.

16:24 Ah, no, my balls!

16:26 Balls done come'd out.

16:30 Oh, now they're all greasy, too.

16:32 Bruh.

16:32 All right, this is going to get worse before it gets better.

16:35 Something is not right here.

16:40 All right, well, something's not right.

16:42 All right, here's what we're going to do.

16:44 So, prevent me from getting really annoyed

16:46 at that, we're going to do the outs, outer joint.

16:50 My patience is wearing thin at this exact moment with that.

16:53 So, today's like March 2nd.

16:55 I really want to have the car running and driving like a week and a half,

16:58 two weeks beforehand.

16:59 That way all the problems that I know we're

17:01 going to find will pop up before we're at Wookies.

17:05 So, uh, April 1st is kind of my rough target.

17:08 Let's flip this back the other way and see

17:10 if we can reconvene on our rear side here.

17:13 Yeah, if you want to learn how how actually

17:15 do this, not silly like I'm doing it right now.

17:18 We did a video on it.

17:19 It's on a 911, but it's basically the same thing.

17:23 Oh, did it fall off?

17:25 Just used it.

17:26 I don't know if you guys have days like this, but holy smokes.

17:29 All right, I need a minute.

17:32 I can't even take my gloves off.

17:33 They're so greasy.

17:36 At the dealer, I would always call this like I got to go take a smoke break,

17:38 even though I don't smoke.

17:40 Basically, you just need to walk away from it for a minute,

17:42 and then usually what happens when you come back to it,

17:44 everything just goes perfect.

18:01 Ouch.

18:05 What the is wrong with this thing?

18:09 There we go.

18:11 700,000 years later, we have our axle ready to go in the car.

18:17 Much more fresher.

18:24 You remember we put our brakes on.

18:25 I'm still working through how I want the cables to run.

18:28 The factory R32 is a hard line down between the rotor and the trailing arm,

18:35 but there's a heat shield that blocks it.

18:37 So, on this side, I have it routed through the trailing arm,

18:40 which if we do that, I'll put a sleeve on it

18:42 cuz I'm worried about like jagged edges inside of here.

18:44 That's option one.

18:46 Over on this side is another variant.

18:48 This is full droop.

18:50 I'm thinking about just drilling a hole and tapping it.

18:52 We just need to make sure we have plenty of flex.

18:54 So, I'm still kind of working through some

18:56 of this, but the shop I will say is very clean.

18:59 I cleaned the floor yesterday.

19:00 My buddy CJ came with his blue R32.

19:03 We re-foamed the blend doors, swapped the dash.

19:05 You can see this dash is all cracked.

19:07 Our ECM came from HPA, so it's properly tuned, ready to go.

19:11 Fuel stuff, which we're going to work on here pretty soon.

19:14 We're waiting on those lines for our rack.

19:16 I ordered some new ones.

19:18 So, we'll get rid of these crusty rusties.

19:20 We need to figure out our oil return line from our turbocharger.

19:24 This is just dash 10 PTFE.

19:26 In the last video, I said, "Hey, I think where it comes out of the oil pan,

19:29 a banjo bolt would be the right fitting."

19:31 in the sense of like space and hose routing.

19:35 And some of you, thankfully, and I appreciate that you said this, said, "Hey,

19:39 be careful cuz the flow rate of a banjo fitting

19:42 might be too low." I got this guy right here.

19:45 Right?

19:45 So, this is the end that would thread into the oil pan.

19:47 This is the end that would go to our return hose.

19:50 It's a little restricted on the inside.

19:52 If you look right in the hole,

19:54 you can see that that there's like supports for the bolt, right?

19:57 Cuz it has to support itself.

19:58 I thought, "Okay, if we use this, I can take it apart,

20:02 go in with a Dremel, Dremel it out so that it's fully open." Then, I found this.

20:07 This is a By the way, these fittings get expensive fast.

20:10 This is a low profile 90.

20:12 So, this end would screw into the pan,

20:14 and then it would stick out a little bit further.

20:17 So, I like the banjo for a fitment,

20:18 but I think this one probably will flow better.

20:20 Then, I found this one, which is a full opening.

20:24 This should flow the most oil.

20:26 And what we're worried about is oil backing up in this line,

20:29 and then backing up the rest of the way up

20:30 the line and blowing out the seals of our turbo.

20:33 So, I think this, coupled with this fitting, I think is the play.

20:37 So, this is another dash 10.

20:39 You see how small this part here is compared to that?

20:42 It's like night and day, right?

20:44 This is probably fine.

20:45 This is a fuel fitting when we're pushing fuel through,

20:49 but when we're trying to evacuate oil as fast as we can,

20:53 I think these are the way to go.

20:55 I'll save all these for another job, I'm sure.

20:57 And I went with PTFE one, mostly cuz I had it.

21:00 Two, even though it's a little less flexible,

21:02 we don't really need it to be super flexible.

21:05 And three, this is supposed to be a little bit more heat resistant than CTE,

21:09 which is just your traditional dash 10 lines.

21:12 It will probably look like something that.

21:14 This There may be a real hold your mouth right situation happening here.

21:18 The cool thing though is once we get this done, we can put our downpipe in.

21:22 I think we can put the subframe in.

21:24 That'll be a big moment.

21:25 I'm going to put that end on the turbocharger

21:27 and we're going to work from the top down.

21:29 We have one other piece of the puzzle over here

21:31 that we need to account for and that's our downpipe.

21:33 Also, how cool is it that we're test fitting things like the downpipe?

21:37 That's really fun.

21:39 This is the other side of our hose that I got to cut.

21:42 If you know of a really awesome way to cut this where it doesn't make

21:45 a huge mess and leave a bunch

21:47 of these little jagged stringy things, please let me know.

21:53 Uh see how nice that went on?

21:55 Tape was worth it.

22:03 Not too bad.

22:04 One way or return line.

22:06 Then we'll all just say a little prayer and hope it doesn't leak.

22:20 This is a big moment.

22:21 We are going to deal with our fuel system.

22:23 Now, when we were putting the tank in the car,

22:26 I had removed the fuel pumps and all these little hoses were so brittle,

22:32 they just crumbled apart.

22:34 While this is not ideal,

22:35 I would much rather this happen while I have this part in my hand than

22:38 while we're ripping through the mountains or something

22:40 and then starve our engine for fuel.

22:42 So, because our car is all-wheel drive, we have a saddle tank,

22:46 which means the exhaust and the propshaft and all that run through the middle.

22:50 So, we have two units, we'll call them.

22:52 We have this one.

22:53 This one lives on the passenger side and this is our actual fuel pump.

22:57 This also has one of two level senders.

22:59 So, you can think of a saddle tank as almost being like

23:03 two separate tanks that the fuel has to transfer back and forth, right?

23:07 When we're driving and we're using fuel,

23:10 we what we don't want is all the fuel to drain

23:12 out of one side and the other side still be full.

23:14 So, that's why we have these two separate units.

23:17 This one is not an electric pump.

23:20 This is called a suction jet pump.

23:23 So, it basically siphons fuel over to the other side.

23:26 It also has its own level sender, and I believe the way this works is

23:30 a calculation between these two sent up to the cluster.

23:33 That's how your fuel gauge actually reads how much fuel is in the car.

23:37 Now that you're fuel pump R32 experts,

23:40 let's talk about how we're going to modify this.

23:42 Because we're turboing it, we need more fuel.

23:44 The HPA kit uses an external,

23:47 basically like a divorced fuel pump setup, which is this.

23:50 I think it goes fuel out of the pump,

23:52 then to this pump, then to the front of the car,

23:55 but please don't use that part as a DIY cuz I really I got to look it up.

24:00 First and foremost, we got to get this guy and this guy not only in the tank,

24:04 but we have to make all the connections inside of the tank,

24:07 which can be a little tricky.

24:08 Lucky for me, there's no gas in it.

24:11 Now, you'll notice I don't have the seal on yet.

24:13 I like to actually do those last.

24:15 And this is the part that really stinks.

24:17 You kind of have to have like your hands in the tank and the pump in the tank.

24:22 I'll tell you, if you're doing this, patience is your friend.

24:27 In order to loosen and tighten these rings, this is going to blow your mind.

24:30 There is a special tool to do this from VW, from Audi, from Porsche.

24:34 And Paul in a video is like, "Nobody ever has the tool." He

24:37 sounds like pimple-faced teenager from The Simpsons.

24:40 Uh well, here you go, Pauly D.

24:41 I have the tool.

24:42 Maybe Paul has got an opportunity now to sell his own version of said tool.

24:48 But really though, don't crank the crap out of these.

24:50 What I always do to make sure I got it all the way

24:52 seated is I'll look at the gap between the ring and the pump.

24:56 And if it's not perfectly flat, you do not have the ring in the right way.

25:00 After I get this done, I can kind of just wash it.

25:03 All the water will dry out.

25:04 And honestly, after that, I feel good

25:07 at least putting the carpet and padding in.

25:09 And I got new factory padding.

25:12 And our man Christian's working on the interior.

25:14 Remember, he has all the interior and I am hyped.

25:17 We're working on Charles's black R32.

25:20 We're doing Alcantara headliner.

25:22 We're doing some special seats for him.

25:23 Doing some special door panels.

25:25 A bunch of the templates already made for him.

25:27 Just cutting them out.

25:29 Certain areas I'll glue and certain areas I don't.

25:33 The glue will keep it from forming to the seat centers and stuff.

25:36 I will just so it stays flat and stuff.

25:38 Because if I don't, it'll bubble up right here.

25:40 Make it harder for the leather to like just relax.

25:43 When you're sewing things up, you always want to have sew marks.

25:46 It makes life so much easier.

25:48 Charles's steering wheel.

25:49 I'm going to sand down everything so the glue has a good bite on.

25:53 I'm going to make templates for it and then sew it up.

26:26 It's going to look so good.

26:27 Especially all the little special pieces that we're doing on it.

26:29 Charles is doing something that I've been wanting to do on a car for a while.

26:32 We're going to perforate material in the center with a custom color behind it.

26:37 A little fancy headliner, too.

26:39 This is it for now.

26:40 Next time you see this, it'll all be wrapped up on the steering wheel.

26:45 I mentioned we had that external fuel pump.

26:47 That's what we're going to work through now.

26:49 So, this This all part of this HPA turbo kit.

26:52 I've said this before, they have turbocharged way more R32s than I have.

26:56 Some of these things though, I might have done a different way.

26:59 So, we are I think getting rid of this clamp,

27:03 which is all fine and good cuz she's yucky.

27:05 So, this is going to sit up in here kind of like this.

27:09 We have to run a new fuel line up to the front,

27:12 and then they kind of like tear in together before they go into the fuel rail.

27:15 Our other pump, we mount it to this bracket right here,

27:18 and this kind of lives like up here.

27:21 I don't love that, and I always worry about anytime you add something,

27:25 you run the risk of it catching on something in the road and ripping out, right?

27:28 Probably overcautious, really,

27:31 but I'd rather be a bit overcautious than ridiculously undercautious.

27:36 We are going to run this new Come here.

27:40 This new fuel line will zip tie it along these lines,

27:43 but it'll live in this channel.

27:47 Hey, yo!

27:50 Yeah, I got it.

27:50 That went better than I had anticipated.

27:53 Anticipated?

27:53 Get your mind out of the gutter.

27:55 I'm just going to kind of loosely place it up there.

27:58 I don't know like how we're going to orient it.

28:01 Not going to do like a permanent situation here with this.

28:04 This is just kind of like a mock-up.

28:07 Let's put an axle in.

28:08 If this were another job of like,

28:10 I don't know, doing a transmission or something,

28:12 this would not be the monumental moment that it is right now.

28:16 This is a huge moment.

28:17 This is a big step to our end goal

28:19 of this video of getting the car on the ground.

28:23 70 newtons for our inner axle bolts, 40 newtons in the back.

28:28 Why is it less in the back than in the front?

28:30 That's a great question.

28:31 I'd love to tell you.

28:32 It's cuz they're smaller bolts.

28:37 You remember the cardboard aided design that we did

28:40 to make a lower shield at the bottom of our transmission?

28:42 Well, now it's time to actually make said lower shield.

28:45 So, here's our little template that I made, engine side, transmission side,

28:50 22 gauge piece of a weldable steel sheet, courtesy of Home Depot Motorsports.

28:57 Oh, this is like $14, by the way.

28:59 As I'm buying this, I'm thinking,

29:00 I totally understand why people take street signs and cut them

29:03 up for the like shields on the bottom of their car.

29:05 I don't recommend doing that, by the way, just to be clear.

29:08 So, um all we're going to do is we're going to just trace this out,

29:11 we'll rough cut it, test fit it, and then we can fine-tune it as we need.

29:16 Let's be real, cardboard often saves the day.

29:20 We use it for designing things, test fitting, making templates.

29:23 I did something similar when we routed

29:25 the battery cable on my RS3 swapped Golf R,

29:28 storage for bolts, organization for bolts.

29:31 What can't cardboard do except survive getting wet or be shipped by FedEx,

29:36 because then it just looks like they kicked it to you.

29:39 Now, we have this jagged, super dangerous piece.

29:42 I'll give you a real nice deal on it.

29:45 We got a loose template, let's test fit it,

29:47 make sure we're close, and then we'll drill some holes in it.

29:50 Like we need to trim a little more out of the top.

29:53 Oh, yeah.

29:54 So, that basically what we're looking at.

29:57 Doesn't need to be fancy or crazy.

30:00 I'll uh I'll probably trim off the end here.

30:04 Got some jagged edges we'll clean up.

30:06 I do want to paint this, though,

30:08 so that we don't just leave this bare metal uh mounted to our transmission.

30:12 Will it look like it came that way from the factory?

30:15 Yeah, probably not.

30:17 Will it be fine for what we're trying to do?

30:19 Absolutely.

30:20 So, you might have noticed uh what Ray called the elephant in the room,

30:24 the giant red elephant parked right behind me.

30:26 This is my red Mark 4 R32, exact same car as this car, just in red.

30:31 Uh it is in here for one main reason.

30:34 That is so when I'm not sure how something

30:36 is routed or the direction it flows or whatever, we can refer to this car.

30:40 This is also my daily driver, so it may be in here sometimes, it may not,

30:44 but I'll tell you it's real nice when you have another car you can

30:47 compare how this is routed and does this go over or under, whatever, right?

30:52 We had this black car apart for basically 6 years.

30:55 So, I feel like it's pretty reasonable

30:56 that I might not remember exactly where everything goes.

30:59 So, if you see it, say hi to it.

31:00 You might remember earlier in this video

31:02 we installed this master cylinder upgrade.

31:05 I'm actually going to remove this.

31:06 Our lines didn't quite reach.

31:08 I talked to Epitech about it and they said you can

31:11 bend the line a little bit and see if it reaches,

31:13 which I don't like that, but it probably would be okay.

31:17 The other major factor is we have no provision for the pressure sensor.

31:21 So, I hit up our boy Swoops.

31:23 He's like, "I got you.

31:24 Send me the stuff." And he is a razor sharp dude.

31:27 I want you to check out some of the work that he does because it is elite.

31:30 If you are in the BW Audi show car space, you know who Swoops is.

31:35 Full trust in this dude to do an incredible job.

31:39 And our R32 is going to be better off for it.

31:43 That is our wrap for our downpipe.

31:46 So, this came with our turbo kit and basically what

31:50 you do is you moisten this and wrap the header,

31:55 downpipe, whatever it is that you're going to wrap.

31:56 We also have a turbo blanket for the turbocharger,

32:00 which leads me to believe that this system is going to create

32:03 a lot of heat and we need to make sure we're managing it.

32:15 So, what we're going to do now is we actually have to stack on like six things.

32:19 So, this is a big piece, more heat treatment,

32:22 more blocking some of the heat getting on.

32:24 This is step one, step two, step three, step four,

32:26 so you don't end up having to take stuff back off,

32:28 put it back on, pick it off, put it back on.

32:35 Uh it's going to need a little massaging, so I'm not going to like really crank

32:38 it down just enough so it doesn't come out.

32:41 Okay, I got our wrapped down pipe.

32:44 I've read a lot of differing opinions about wrapping the flex section.

32:49 So I'm going to leave it.

32:50 Some said to wrap it separate.

32:52 Some said they just wrapped right over it.

32:54 Now I'm not going to tighten that V-band clamp and here's why.

32:58 That may be out of alignment up on the turbo which

33:00 means the whole exhaust is going to be out of alignment.

33:02 So I'm going to leave that loose then we can get this pipe on.

33:06 Our catalytic converter will go here and then

33:09 our resonated section will go a little bit further back.

33:12 We can't do the muffler and all that yet cuz we got to still tighten down all

33:15 the rear suspension but this will at least start

33:18 to get our alignment of our exhaust in play.

33:22 We are one step closer to spooley boy

33:25 Wookiee noises and that really that's so exciting.

33:30 Clearly clearly I'm just clearly I'm an idiot.

33:39 Clearly I should shut the hell up and pay attention to what I'm doing.

33:42 When I was talking earlier about not locking

33:45 the downpipe down it's because of what happens downstream, right?

33:50 If I fully tighten it where it's at right now our exhaust instead of being

33:55 like kind of level to the bottom of the car might be hanging down.

33:59 It might also be slammed up into the body and you may not see that here which is

34:04 the downpipe but as you get more of the exhaust

34:07 on the problem gets worse and worse and worse.

34:09 So I'm going to put this pipe on.

34:11 I feel confident tightening it down.

34:13 The next pipe we can slip in but I'm not going

34:16 to tighten it down cuz we may have to rotate that pipe.

34:18 We may have to slide it back a little, slide it forward a little and we really

34:22 won't know that until we put the muffler on.

34:24 So this pipe is a resonator pipe.

34:27 She's going to go up here.

34:29 Just making sure I'm not going to block anything that I need to tighten down.

34:33 Jesus Louise.

34:39 What the There we go.

34:46 Okay, and then this is where our muffler will bolt on.

34:50 And then we have our tips that'll obviously come out at the bumper.

34:54 So, another one of those big steps, right?

34:56 It doesn't seem like a lot.

34:58 The only thing I'm a little worried about right this minute

35:00 is how many little pieces we still have to piece together.

35:03 And I'm hoping I'm making the right choice by doing the bulk of it

35:07 and then kind of going back and doing the fine-tuning, but we'll see.

35:11 Now, we got the main pipes on, everything minus the muffler.

35:15 I could in theory tighten the downpipe back down,

35:19 but I'm going to wait till we get the muffler on and the tips on.

35:22 That way I can fine-tune the fitment of our tips.

35:25 We do have one more axle we got to take out and rehab.

35:28 You've seen what the rehab looks like.

35:31 It's going to be the same as the other ones.

35:33 So, I'm not going to bore you with those details.

35:38 Old and busted, new hotness.

35:41 Except it'll look new the next time I do it.

35:50 A vital step before we get our subframe and steering rack and front sway

35:54 bar in the car is going to be replacing these hard lines on the rack.

35:58 Now, they weren't leaking and we could probably run them and be okay.

36:02 However, with how crusty they are, I don't think it's worth the risk,

36:06 especially at this point point in our project anyway.

36:09 This is apparently a really common issue.

36:12 I found a company in Canada that makes the hard lines.

36:15 Unfortunately, they're not selling them right now.

36:17 So, thanks to somebody with a TT pointed me in the direction of these.

36:22 Now, these are just dash four lines with these fittings right here.

36:28 The company I got them from, I tried to message them

36:30 to make sure it fit in our 32 cuz they don't list it.

36:33 Couldn't do it cuz their website wasn't working.

36:35 So, if you have a question, you may or may not get a response.

36:38 Hopefully, you get something better than I did, which was nothing.

36:40 But either way, let's all hope and pray

36:43 these actually come come out the right way.

36:46 Now, you do need to reuse these clips right here.

36:48 And of course, this one down here is the one that is

36:52 going to hit the subframe when you try and take it out.

36:55 We may try and rotate that.

36:56 Basically, our kit is two lines, the short one and the long one,

37:00 four of these fittings right here, and then seals to go along with it.

37:04 So, these basically just slide in like that where the line was.

37:08 Pretty straightforward.

37:12 All right, there we go.

37:12 That should be enough.

37:17 So, you're going to have to unbolt the rack either way,

37:19 cuz I couldn't get the line out from underneath it, but there she is.

37:23 I'm going to take these and see if we can get some new ones made.

37:25 So, that's going to go there.

37:27 So, you might end up having to like clock

37:29 these and play around with the clocking of it,

37:31 but I think it's going to be okay.

37:32 Let's clean these holes up, put our lines in.

37:49 So, I think we're going to be good on our long line.

37:53 I'm a little worried about our short line.

37:56 It's like an inch too short.

38:00 Hear me out.

38:01 If we just got an extension for right here, I think we could make it work.

38:06 I don't love having to add another fitting to this situation,

38:11 but if that's what gets it done, that's what gets it done.

38:18 I ended up finding this little retainer that I used.

38:20 I don't love that it's blue, but it's going to get covered up anyway,

38:25 which brings me to the two other things we have to do

38:28 to our subframe power steering rack before we put it in the car.

38:32 One is our freshy power steering lines.

38:35 These are fully flexible lines.

38:36 Now, we don't have to run those hard lines that were all rusty crusty.

38:40 These two banjo fittings are two different sizes.

38:42 I believe the top one is 16 on 1 and 1/2 and the bottom one is 14 on 1 and 1/2.

38:48 What we did on the Lupo is I substituted the banjo fittings

38:52 for a 16 by 1 and 1/2 to a like a dash eight, I think, which works really well.

38:58 For this one, because I was able to get these, this is what we're using.

39:01 Now, I'm not going to tighten these down all

39:03 the way because we need to mess around with our routing.

39:07 I'm just going to snug these up enough to hold it in place.

39:11 Uh heat shield next.

39:13 We got trim the end off.

39:16 I'm just going to loosely put this shield

39:18 on and then we'll kind of recalibrate it from there.

39:21 I think it was pretty bent up when we started anyway, so NBD.

39:25 Clean it up a little bit.

39:27 We're good to go.

39:29 This is actually meant to mount to the factory bracket,

39:32 and since we replaced our bracket with that solid piece from T Rule,

39:36 it just makes mounting a little bit more challenging.

39:38 So, I think what we're going to do now is

39:40 just flatten this out a little bit to get more coverage.

39:42 Now, I also have this extra shield.

39:45 We could probably just use this too.

39:48 I'm going to get the rack in the car.

39:50 We're going to see cuz I'm also a little worried about fitment,

39:52 uh but we got the important parts done and I

39:55 think we're just going to lower the car down on it.

39:57 Getting the subframe complete in the car is big.

40:02 These are the alignment dowels that I made.

40:05 Now, you may be thinking, Charles, that sounds so fancy.

40:08 And you'd be right, it is fancy,

40:09 but really all it is is subframe bolts with the heads cut off

40:12 and a little slot drilled in it so I can undo it with a screwdriver.

40:17 And all this is going to do is help us get the four

40:19 holes in the subframe aligned and make my life a little bit easier.

40:24 So we're going to go one in the front, right there.

40:26 So then when we lower the car down, we can shift the whole toolbox,

40:31 which is what that's sitting on, into place

40:34 and then start the bolts, send it up.

40:37 Mount down.

40:38 Mount down.

40:40 If you saw the Mustang series where Paul said that a hundred times,

40:43 which I thought was hilarious,

40:44 some people got really sad about that, which I thought was really weird.

40:49 Whatever.

40:50 We have the two dowels that I put

40:52 in, and then we have the connection for the steering shaft,

40:55 which connects to the steering wheel.

40:57 Right in the hole on the front side,

40:59 and then we can raise it up to do the last bit.

41:03 Let's go.

41:08 Let's go.

41:11 Also, if you didn't know,

41:14 this is the only way as a technician you can stand and have the lift go up.

41:19 One leg crossed over the other, one finger on the button, one hand on hip.

41:26 Just like this.

41:28 Car doesn't go up if you don't stand that way.

41:31 If you haven't guessed, the theme of this series is install bolts,

41:36 but not actually torque them down.

41:37 And typically, I would tell you never walk

41:39 away from a bolt that's not properly tightened.

41:41 Because we're coming back and like marking all the bolts, this will be fine.

41:46 Plus, look, you know, are we going to have to drop this subframe again?

41:49 I hope not, but it's possible.

41:51 I just want to make sure I don't

41:52 have to replace some bolts that I just replaced.

41:54 Just going to celebrate for a very brief period of time.

41:58 We also have our dog bone to rebuild, too, which I kind of forgot about.

42:01 So we got engine mounts from Vibra-Technics.

42:05 Part of that kit is going to be

42:07 replacing the bushings inside of our dog bone mount.

42:10 Now, if you wanted to, there are kits that replace this one as well.

42:14 I think Powerflex makes one.

42:23 So, our first step is going to be to get all

42:24 this stuff cleaned up cuz we don't want all this old yuck rubber.

42:28 You don't need to go nuts here.

42:37 There's a tight setup and a comfort setup.

42:39 We're going to go with the tight setup first.

42:41 On the backside of that, we do three 3 mils.

42:54 We have victory.

42:55 So, fully rebuilt on the back end, on the tight setting.

42:59 There's still flexibility in the front.

43:01 We'll see how it does.

43:02 Like I said, I've never ran these engine mounts before,

43:05 so I don't know how they're going to behave.

43:07 We'll see.

43:08 While we're here, let's go ahead and get our sway bar on.

43:12 Rear sway bar, that is.

43:13 This is our H&R rear sway bar, the one that we got to go to the factory

43:18 and see how they actually make the stuff, which was the absolute coolest.

43:26 Let's test fit some wheels.

43:29 I got some very non-freshy Aristos.

43:32 These are the wheels that were on the car when I got it.

43:36 Drive by feel, these are most certainly not

43:38 the wheels that are going on the car.

43:39 So, I got a new set of Aristos.

43:42 So, they're going to look just like this, except nice.

43:45 In my opinion, the Aristos are the best looking wheels on an R32.

43:48 They're the wheels that came on the car, I think they look great.

43:51 The new speed RSE 10s, which I had on my blue car,

43:55 were designed off of that wheel, so those look pretty good, too.

43:57 There's other wheels that look great, right?

43:58 Like, if you have BBS CHs, amazing.

44:01 I really like these wheels a lot.

44:02 To be able to get a brand new factory set of wheels for like 1,400 bucks,

44:06 I think it's a home run.

44:07 I might get these rehabbed anyway,

44:09 have them powder coated coated like a deep gold,

44:12 kind of like the wheels that were on the Mark VIII,

44:14 but that's a problem {slash} project for another day.

44:18 The project now, car down, test fit wheels.

44:21 We already test fit the back, definitely need probably 15 to 20 mil spacer.

44:25 The front, I don't know.

44:27 Oh boy, it's It is close.

44:30 Like we're going to have to be conscious of where we put wheel weights.

44:35 It's how tight this fitment is.

44:36 Just think of how good this is going to look without a crusty dusty wheel.

44:46 Uh so, basically what we have going on here

44:48 is we have a an extreme toe out situation,

44:51 and we have one that's like pretty close,

44:52 and the one that's like way off the reservation.

44:55 Not even close.

44:56 If we put the car down right now, as it is,

44:59 odds are the passenger side tire right into the fender.

45:03 Cuz we don't know how low this car is going to be.

45:05 I had a super good idea, and that's to set the car down on a race ramps before

45:11 we get wild and crazy and just set it on the ground.

45:14 This way, we'll be able to lower it down and I

45:16 can climb underneath and just make sure we're not hitting anything.

45:18 Remember, we still have a bunch of stuff not attached.

45:21 And let's see how she looks.

45:24 By the way, this is the only car in the world on this suspension,

45:26 so this is pretty epic.

45:35 That's on wheels, friends.

45:37 That is on wheels.

45:39 It I want to be like, "Oh my god,

45:42 IT LOOKS SO GOOD." EXCEPT we don't have a fender on this side,

45:45 so we got to walk of shame over to the other side and see how it looks.

45:49 I like it.

45:50 The ride height is great.

45:52 We're cambered out in the back, so camber gang,

45:54 but I think the front ride height is exactly where we want it.

45:58 This moment to me might be the biggest moment of this project so far,

46:02 Because this is where we can finally start to see this car

46:06 coming together and then picture like ripping at the tail of the dragon.

46:11 I'm pretty excited.

46:12 Even though I'm sitting here like uh the villain in Inspector Gadget,

46:18 which I can't remember what his name is.

46:19 The brakes look amazing.

46:21 You don't really notice the calipers,

46:23 but I guarantee you in the sunlight, when the sun hits it, room.

46:40 I just set the coil overs roughly halfway,

46:43 but I think we are almost exactly where I want this car to be.

46:58 How do you like that?

47:00 For the first time in over 5 years,

47:02 this car is on its own suspension, its own wheels, sitting on the ground.

47:06 The only thing that could make this better is if we could hit the key

47:09 and start it up and I could drive it back in instead of having to push it.

47:11 But, this is a huge moment and I'm really excited.

47:14 So, I need to get this back in the shop.

47:16 Obviously, we can't leave it out here.

47:18 This is what I'm going to say.

47:19 I have about 3 weeks before this car has

47:21 to be running and driving so we can shake everything down.

47:23 So, in the next video, my goal is to start it,

47:26 have it running, and then find all the problems and things that we missed.