PUTTING THE BOOT IN #Volkswagen-Jetta-Mk4-1.9TDI
We don’t tend to get too excited over modified Boras these days because we very rarely get the chance, but Anthony Warrior’s example literally stopped us in our tracks. Just look at it! Words: Elliott Roberts. Photos: Si Gray.
It’s funny, but looking back over the years, we’ve only ever featured a small number of Boras on these hallowed pages – the majority of which have been created across the pond. I’d go so far as to say you could probably count the amount of full-fat, UK-built Boras on one hand. The booted version of the Golf just never really took off here in the UK, largely because people didn’t deem it as sporty as the hatchback or as practical as the estate. Understandably we’re more than a little bit excited to bring you coverage of what Anthony Warrior’s vision of a sporty Bora should look like. It’s more than simply a breath of fresh air… it’s awe-inspiring!
Despite being very fond of cars from an early age, the engineer from Darlington didn’t pass his driving test until he was 21! “I was certainly a late starter, that’s for sure. I remember as a kid that my dad was always a Ford man, but for me it was hearing my friend’s Mk3 Golf VR6 for the first time. That triggered my passion and love for all things VW almost instantly,” he confessed. Despite initially being into the idea of getting a Golf, due to owning quite a large dog Anthony’s other half, Claire, insisted that it had to be a five-door: “I’m not keen on five-door Golfs to be honest,” said the 35-year-old, “so I started looking at Boras and ended up buying this one.”
The car might have only had one previous owner and been low mileage with just 50k miles on the clock, but it was totally bone stock and that just wouldn’t do. “Okay, I can honestly say that all I ever really planned originally was a set of wheels and perhaps a remap. Now, some 12-years, five sets of wheels, three sets of coilovers, air ride and £1000s spent on bodywork and interior, I can safely say I didn’t intend to go this far.”
Anthony’s modified journey didn’t begin all that positively though, with a set of 18” Audi A8 replica wheels shod in equally awful balloon tyres being his first step on the ladder. It was actually PVW’s very own Dave Kennedy, or rather his Bora project, that helped Anthony see the light: “I have to say that I’ll always remember watching the progress of Dave’s black car… And those huge wheels he attempted to fit to it.” Needless to say after the rep’s came a set of BBS RCs, followed by a couple of sets of BMW wheels before Anthony finally wound up with his current set-up: “The wheels were something that took ages to get right, especially as they’re 20s, which nobody had really done at the time or certainly hadn’t pulled off,” he said. Anthony claims it was a bit of a gamble buying the genuine Ferrari wheels as it was a big financial outlay, but when they came up for grabs he accepted the challenge. Talk about trial and error, too: “I knew I’d need to run adaptors and the fronts were pretty straight forward being a pair of 25mm items. Out back the adaptors were quite large at 38mm, but that wasn’t a problem until I offered the wheels up before ordering tyres. For some reason one of the wheels poked out a bit more than the other, so I had to take the adaptors to work and have 2mm machined off one of them.” It’s quite a common problem on the Mk4 platform where the axle never sits perfectly in the arch. You don’t actually notice when running standard ride height as there’s lots of clearance in the wheel arches. It’s only when you’re go low and are dealing with millimeter clearance that it becomes apparent.
Talking of air-ride, after running numerous sets of coilovers over the years Anthony finally decided to bite the bullet and opt for air: “I decided I was sick of bouncing the 130-mile round trip to and from work, so invested in and Air Lift Slam set-up.” Obviously the install has progressed over time, from the original set-up he fitted in his in-law’s freezing garage, to the carbon-clad, hard-lined work of art you see today. “The air tank is still the original item, but now wears a carbon-fibre skin with copper strands running through it, which Paul from C6 Carbon said was a must-have to tie-in with my copper hard lines.” Since the initial air install, Anthony has also fitted poly bushes throughout and also added IDf drop plates to allow the amount of camber needed to run 11s out back.
It’s obvious that Anthony, who is an engineer by trade, is pretty proud of what he’s achieved with the car, especially as he’s carried out virtually all of the work – other than the paint and carbon – himself! Believe it or not the all-metal, wide-body makeover was carried out around six years ago (before the air ride and Ferrari wheels, in fact) when Anthony was still on coils and looking to fit some wide 6-series BMW wheels. “The bodywork had to be one of the most time-consuming parts of the whole project but then it was done twice. I wanted the arch lines to be as close to factory as possible, to keep it subtle.” As if widening the car by around 4” front and rear wasn’t going to be pretty damn obvious. The thing is, despite the added girth and crazy-wide wheels filling each corner, Anthony almost pulled off the whole subtle thing. For some reason though, he wasn’t really happy: “I seemed to fall out of love with the car for a while at this stage and it just got used and abused really.” It was only after talking to his friend, Dentman that Anthony got the bug again: “He suggested I should take the car to Autospray in Darlington, which I did. We discussed my plans and I quickly decided they were the right guys!”
Apparently the car was only booked in to have the wide-body conversion reworked, which should have taken a week, but that soon changed to include smoothing the doors and rear bumper, repainting the front bumper and bonnet, then doing the B-pillars and rear door quarterlight bars gloss black, plus adding new window rubbers, clips and screws: “Four weeks later it was ready for show season. That was four years ago, and since then it’s been back ever year to have little bits added or improving,” he said. The car has got continuously smoother as time has gone on. However, we love how the gloss black external parts break up the Satin silver colourcoding so it’s not too over powering.
On the engine front Anthony hasn’t gone too overboard, but he did admit to getting a little fed up being left behind by his mates whenever they went out in their cars together: “I needed to do something, so I took the car to Revo for a remap, but that turned out to more than a simple flash. We actually had to remove the ECU and install a new chip. What a difference it made out on the open road, though.” After a quick rolling road session it showed 152bhp and 270lb/ft of torque: “I was pleased but figured we could do a little better, so went for a full Milltek system from the turbo back, with de-cat pipe, too." With the addition of an ITG panel filter and Allard EGR delete, the final outcome was 165bhp and 297lb/ft and Anthony was finally happy! Having driven the car for best part of a year with the tiny stock brakes hidden behind those monster 20” hoops, Anthony was ready to up his game again, especially now he had a bit of extra power, too: “Even though I’d fitted a 312mm TT set-up up front they still looked small and the standard rears we just embarrassing, so a set of fourpiston Ferrari Brembos were sourced to replace the fronts. Then all I had to find a set of suitably large discs and make them fit,” he smiled.
After quite some time spent searching, Anthony eventually found a set of 400mm Alcon discs originally intended for a Jaguar XKR: “First these needed redrilling to fit my 5x100 hubs, then the bell housing needed machining down so the wheels would clear them.” And this was before he’d fathomed out how to make the calipers fit: “I started with cardboard templates and using wooden blocks to get the measurements for the adapters right. Then I bought two pretty large bits of steel, which were drilled and milled for around ten hours apiece. I went a bit over the top getting them as smooth and shiny as possible,” he said. Anthony claimed by the time it came to the back he’d run out of ideas, not to mentioned money: “I figured I’d got a perfectly good 312mm set-up going spare now, so why not just convert that to fit the back?” How hard could it be? “Well, after a bit of drilling, cutting, grinding and lots of swearing they went on.”
Although hard pushed to choose his favourite single modification, Anthony admits that he is particularly fond of the way the interior came together as a whole: “I just love the Recaros up from and am so pleased Paul made me do the Mk3 Rocco rear bench conversion, too. I love all the carbon work Paul’s done inside as well, then there’s the TT dash which tops it all off for me.” That said, the dash swap was probably the hardest part Anthony had to tackle himself: “I thought, how hard can it be?” Turns out, pretty damn hard! “I needed modified clocks because my car’s a diesel and they never made a Mk1 TT diesel, then the steering column had to be lowered and brought backwards,” he continued, “and because I did the full centre-console, the gear linkage had to be modified so I could select all gears. This, along with all the wiring and installation of the electric heater box – as my car didn’t have climate control – made it more than a challenge.” It was worth it in the end, especially with the diamond-stitched leather top, tying it all in nicely with the rest of the trim.
We asked Anthony what he’d change about the car if anything and he had this answer: “I wouldn’t really change a thing other than just doing it the right way the first time around, rather than rushing in and regretting it after.” As for the future, he’s going to look at cleaning the bay up, tucking some wiring and adding some more carbon: “Of course more carbon, lots and lots of it!”
ENGINE: 1.9-litre PD 115 TDI with custom chip (producing165hp and 297lb/ft), 3” down pipe and de-cat, #Milltek
non-resonated system with twin-exit back box. Allard EGR delete pipe, #ITG
panel filter, Touran engine cover painted crackle black, #Forge
short shift kit
CHASSIS: 8.5x20” and 11x20” Ferrari 599 HGTE three-piece forged wheels by OZ with polished lips and faces mounted on G23 adapters (25mm front, 38mm and 36mm rear) with 215/30 and 245/30 Nankang tyres respectively. #Air-Lift-Slam-Series
front struts, #Air-Lift
tapered rear bags, #Air-Lift-V2
compressor and five-gallon tank, #Powerflex
poly bushed all round, IDF rear correction plates. Ferrari four-pot front callipers with custom machined brackets and 400mm Jaguar XKR Alcon discs re-drilled to 5x100 with machined-down bell housings, Audi TT 312mm front brake set up adapted to fit the rear with callipers painted yellow to match fronts
EXTERIOR: Full respray in the original Volkswagen Satin silver, arches extended 40mm each side in metal, smoothed factory bumpers blended in the extended arches (front and rear), smoothed rub strips, side repeaters and roof aerial deleted, genuine Golf Anniversary front valance modified to fit and painted gloss black, genuine Golf Anniversary side skirts, Bora 4Motion rear valance (painted gloss black), genuine OEM xenon headlights with twin, centre running lights and turn signal relocation, all-red rear lights with gloss black housings, Lupo stubby mirrors (electric and heated) with clear glass and gloss black basis, new window rubbers all round, gloss black B-pillar and rear door window bar, gloss black grille, bumper grilles and scuttle tray, genuine Jetta GLI grille (carbon skinned), aero wiper arms and blades, gloss black rear towing eye cover
INTERIOR: Full Mk1 Audi TT dashboard and centre console conversion with diamond stitched leather top and custom instrument cluster, modified steering column and shortened gear linkage relocated OB2 port, Climate Control retro-fitted with heater box change, Recaro Sportster CSs in black leather with gloss black inserts, Mk3 Scirocco rear seats retro-fitted and trimmed to match fronts, six-speed Beetle Turbo gear knob, Momo 280mm wheel, carbon-skinned door card tops (with deleted door pins), steering column cowl and TT knee bars (all carbon skinned in Audi small weave by C6carbon). Black perforated leather roof lining and A, B and C pillars, Golf Anniversary black grab handles, interior light, seatbelt tops, sun visors, alarm sensors and rear view mirror, Passat mirror adjuster, leather door cards all round with custom audio builds in front doors. Brushed-aluminium door grabs, custom bootbuild with floating floor (lit by LEDs), five-gallon tank skinned in small-weave carbon with copper strands running in the weave, copper hard line installation, twin AVS polished water traps, polished compressor fittings and polished bulkhead fittings
AUDIO: JL Audio MBT-RX Bluetooth receiver, #Precision-Power-Par245
five-band EQ mounted where head-unit would have been, JL Audio XD 1000/5v2 amp with copper/carbon-skinned cover to match air tank, JL Audio TW3 12” sub in non-ported custom enclosure, 8 x 6” Jehnert woofer speakers 2 x 4” Jehnert mids, 2 x 2” Jehnert tweeters, Jehnert crossovers and lots of Dynamat throughout
SHOUT: My wife, Claire for putting up with ‘that car’, Paul at Deluxe Detailing for looking after and preparing the car, Mike and Vicks at Kleen Freaks for all their support, Paul at C6 Carbon for all the carbon goodies, Pete, Adie and the crew at Autospray Darlington, Justin at Car Spa Darlington, D&W Wheel restorers for the powder coating, Rob at JL Audio UK, plus Lee, Woody, Roger, Ricky and lastly my buddies Dentman, Shaun, Begley, Wardizzle, Cuzy and Nathen
It’s obvious that Anthony is pretty proud of what he’s achieved with the car, especially as he’s carried out virtually all of the work himself.
I just love the Recaros up from and am so pleased Paul made me do the Mk3 Rocco rear bench conversion, too.
Recaro CSs are pretty special up from but Scirocco rear bench is a genius addition.