Jump to content
polo6n2g40

slow progress

Recommended Posts

polo6n2g40

a friend of mine asked me to put a 20v turbo in his mk2 golf gti 1.8 8V

i told him when he had all the parts to complete the build let me know and i'll make a start, well the car arrived 2 weeks ago wit a boot full of parts and boxes.

mk220v101112001.jpg

i started stripping it down last weekend

mk220v101112002.jpg

mk220v101112003.jpg

front end off

mk220v101112004.jpg

mk220v101112005.jpg

block out

mk220v101112006.jpg

1st clean

mk220v101112007.jpg

Edited by polo6n2g40

Share this post


Link to post
Share on other sites
polo6n2g40

servo had to come off to access the loom

mk220v101112008.jpg

mk220v101112009.jpg

dash out in preperation for new pedal box

mk220v101112011.jpg

unfortunately he's sourced the wrong pedal box so needed some modification

mk220v101112012.jpg

mk220v111112002.jpg

mk220v111112003.jpg

mk220v111112004.jpg

removed the accelarator cable pull off the old pedal

mk220v111112005.jpg

and slid it onto the new pedal

mk220v111112007.jpg

mk220v111112008.jpg

Share this post


Link to post
Share on other sites
polo6n2g40

the car was being converted to hydraulic clutch which means flatting a section of the bulkhead and drilling a hole to mount the m/c

mk220v111112010.jpg

mk220v111112012.jpg

mk220v111112013.jpg

mk220v111112014.jpg

new hole to reroute the loom

mk220v111112015.jpg

Share this post


Link to post
Share on other sites
Veedub

you dont hang around will keep a close eye on this one :thumbsup:

Share this post


Link to post
Share on other sites
polo6n2g40

loom retaped and fitted

mk220v111112016.jpg

16v mk3 cable change box required minimal modification

mk220v111112018.jpg

mk220v111112019.jpg

i was ready to fit the engine but unfortunately my friend had overlooked engine mounts :lol: also forgot throttle cable, exhaust, bought the wrond DP from qpeng and several other parts so had to abandon it awaiting more parts

well he got a couple of vital parts over to me during the week so started again today

clutch line all fitted with slave and gear linkage with servo, trimmed M/C and mk3 fluid res with take off for clutch

mk220v111112020.jpg

new mount to use the mk4 5 speed box

nozmk220vt241112002.jpg

100mm 16v mk3 driveshaft flanges

nozmk220vt241112004.jpg

nozmk220vt241112005.jpg

Share this post


Link to post
Share on other sites
polo6n2g40

engine perched

nozmk220vt241112007.jpg

nozmk220vt241112008.jpg

2nd clean

nozmk220vt241112009.jpg

nozmk220vt241112010.jpg

nozmk220vt241112011.jpg

loom split into lighting loom and engine loom and taped

nozmk220vt241112012.jpg

that is all for now, got bored of the rain and cold. few more bits i can get on with but i am quickly running out of parts, hope he come through with some more soon....

Share this post


Link to post
Share on other sites
polo6n2g40

only half a days work today, off to look at a new car for the mrs

started to mount the header tank

nozmk220vt251112001.jpg

modified the bracket to fit the car and the mk4 header tank

nozmk220vt251112002.jpg

welded nots on so i can use allen bolts

nozmk220vt251112003.jpg

nozmk220vt251112004.jpg

welded the bracket to the car

nozmk220vt251112006.jpg

nozmk220vt251112005.jpg

test fit

nozmk220vt251112007.jpg

bit of paint

nozmk220vt251112011.jpg

fitted

nozmk220vt251112013.jpg

nozmk220vt251112015.jpg

nozmk220vt251112014.jpg

bonnet clearance

nozmk220vt251112008.jpg

nozmk220vt251112009.jpg

Share this post


Link to post
Share on other sites
polo6n2g40

also trimmed fuel lines to length and connected them

nozmk220vt251112010.jpg

and there was a lot of shortening / resoldering of the loom needed

nozmk220vt251112017.jpg

nozmk220vt251112018.jpg

nozmk220vt251112019.jpg

nozmk220vt251112020.jpg

nozmk220vt251112021.jpg

nozmk220vt251112023.jpg

nozmk220vt251112024.jpg

nozmk220vt251112026.jpg

nozmk220vt251112027.jpg

nozmk220vt251112028.jpg

Share this post


Link to post
Share on other sites
polo6n2g40

have to say the massive bundle of earth wires was not me i reworked it with three smaller wires i worked into the stand alone loom and routed so can be eathed on the main chassis earth.

hoping to get the fmic mounted on the front panel so i can order some boost hoses and hard pipes so i can mock up a nice tidy boos pipe run from turbo to fmic and will also be making a new Turbo intake pipe.

Share this post


Link to post
Share on other sites
erixtar1992

Fair play man! U charging him much for the work?

Share this post


Link to post
Share on other sites
Cooki3

Looks good as always Olly :)

Edited by Cooki3

Share this post


Link to post
Share on other sites
polo6n2g40

today i needed to get the fmic fitted to the front panel, i was hoping to get some boost pipes ordered today for tomorrow but my mate has been uncontactable :x

he's gone for a sprinted fmic, not my first choice but hey ho

i made up a couple of brackets to fix the fmic to the slam

nozmk220vt271112001.jpg

nozmk220vt271112003.jpg

got it sitting where i wanted and welded them in place and welded nuts to the back

nozmk220vt271112004.jpg

once that was sitting right i trial fitted

nozmk220vt271112007.jpg

nozmk220vt271112006.jpg

nozmk220vt271112010.jpg

nozmk220vt271112011.jpg

i wanted to make a bracket to make the intercooler more secure so found a bracket in my scrap bin, cut it to size and welded a nut to the back

nozmk220vt271112014.jpg

worked out where it needed to be

nozmk220vt271112016.jpg

and welded it in place

nozmk220vt271112022.jpg

threw a bit of paint on

nozmk220vt271112024.jpg

and trial fitted

nozmk220vt271112025.jpg

nozmk220vt271112026.jpg

Share this post


Link to post
Share on other sites
polo6n2g40

next was the rad, the one he provided was no use so decided to use the mk2 gti item. with the fmic it could no longer sit in place, so found a motorbike headlight bracket in the scrap bin and lopped a bit off and cut to size

nozmk220vt271112015.jpg

worked out where it needed to go

nozmk220vt271112017.jpg

and welded it on

nozmk220vt271112018.jpg

threw a bit of hammerite on

nozmk220vt271112023.jpg

and sat the rad in place

nozmk220vt271112021.jpg

nozmk220vt271112028.jpg

before i fixed it in place i thought i'd fit the fan and battery to make sure nothing was in the way

nozmk220vt271112029.jpg

nozmk220vt271112030.jpg

nozmk220vt271112031.jpg

with the battery in it seems the boost pipe path was going to be tight so layed the rad forward slightly

nozmk220vt271112037.jpg

and modified the bracket

nozmk220vt271112038.jpg

a little more room but not ideal

nozmk220vt271112039.jpg

all in

nozmk220vt271112035.jpg

nozmk220vt271112036.jpg

Share this post


Link to post
Share on other sites
polo6n2g40

also managed to do a couple more bits, trial fitted the washer tank and mounted the catch can

nozmk220vt271112034.jpg

nozmk220vt271112033.jpg

and fit the modified 3" cable driven TB

nozmk220vt271112032.jpg

and finally tried the grill back on before i packed up

nozmk220vt271112041.jpg

tomorrow will probably be wasted now, if the boost pipes had been ordered today as hoped they would have been here in the morning but i guess i'll be waiting around now for more parts :-(

Share this post


Link to post
Share on other sites
Ashi

looking good :D wish i had the motivation to do stuff in the rain lol and i own a garage :o

Share this post


Link to post
Share on other sites
Jake Ellis

Fair play bud! and ashi same! seems he always works in the rain.. well the couple of times I've been he was always outside on the bora

Share this post


Link to post
Share on other sites
polo6n2g40

managed to get the hoses and pipes ordered today so hopefully they'll arrive tomorrow.

i just spent the morning tidying the loom, made a new section for brake res fluid sensor

nozmk220vt281112001.jpg

tidied and shortened some of the scuttle loom

nozmk220vt281112002.jpg

nozmk220vt281112003.jpg

tidied up the looms on the passenger chassis leg and crimped on new earth terminals etc

nozmk220vt281112004.jpg

fitted oil sensors and connected loom

nozmk220vt281112005.jpg

refitted scuttle panel

nozmk220vt281112006.jpg

and started to make a bracket for the throttle cable

nozmk220vt281112008.jpg

nozmk220vt281112007.jpg

Share this post


Link to post
Share on other sites
polo6n2g40

BOOST HOSES ARRIVED :thumbsup:

i jumped straight to it and chopped all the hoses down and made a Turbo intake pipe before i realised i wasn't taking any pics

nozmk220vt291112001.jpg

nozmk220vt291112006.jpg

next was to tackle the rad hoses

nozmk220vt291112014.jpg

nozmk220vt291112015.jpg

new silicon bends

nozmk220vt291112013.jpg

trimmed and tried

nozmk220vt291112020.jpg

trimmed again

nozmk220vt291112021.jpg

fitted

nozmk220vt291112022.jpg

nozmk220vt291112023.jpg

top hose was a bit easier and joined with 32mm OD 2mm wall alloy tube

nozmk220vt291112024.jpg

nozmk220vt291112025.jpg

nozmk220vt291112026.jpg

next was the throttle body to intercooler pipe, trimmed the first bend to get it where i wanted

nozmk220vt291112007.jpg

then the reducer

nozmk220vt291112008.jpg

trimmed and fitted

nozmk220vt291112009.jpg

nozmk220vt291112010.jpg

nozmk220vt291112012.jpg

once that was done i started to look at the fmic outlet

nozmk220vt291112016.jpg

also ordered some 8mm blanks

nozmk220vt291112027.jpg

and fitted one to the outlet on the rad

nozmk220vt291112028.jpg

Share this post


Link to post
Share on other sites
polo6n2g40

the mk3 front engine mount arrived so i droped the front back off, fitted the mount which also meant i could fit the starter motor and finish the loom in that section

nozmk220vt291112029.jpg

nozmk220vt291112030.jpg

nozmk220vt291112031.jpg

and also fitted the forge sai blanking plate

nozmk220vt291112002.jpg

nozmk220vt291112003.jpg

nozmk220vt291112004.jpg

quick pic as it was getting dark

nozmk220vt291112033.jpg

will get some new cutting discs and mock up the turbo to fmic boost pipe then take it with the inlet to the ally welder

Share this post


Link to post
Share on other sites
KiZ

top work as usual mate!

Share this post


Link to post
Share on other sites
Elijah

Well impressed with this.

Share this post


Link to post
Share on other sites
polo6n2g40

thanks for the comments so far chaps :-D

got up this morning, was supposed to be fitting coils to my mates A4 and mocking up the boost pipe for the golf. mate turned up so told him he could take me to get som cutting discs. on the way some clever person in a mondeo cut off two cars and caused a nice little smash and wrecking the front of my mates car. :x

after a couple of hours faffing round and waiting for recovery i got back to mine and went to get some cutting discs, got back to mine and started mocking u the pipe.

beads trimmed

nozmk220vt301112001.jpg

bends trimmed

nozmk220vt301112002.jpg

trial fitted

nozmk220vt301112003.jpg

nozmk220vt301112004.jpg

nozmk220vt301112005.jpg

bends trimmed again and straight section fitted

nozmk220vt301112006.jpg

nozmk220vt301112007.jpg

and all stripped out and taken to be ally welded

nozmk220vt301112008.jpg

i will trim another 10mm out of the Turbo Intake Pipe to give a little extra clearance when i get the pipes back

Share this post


Link to post
Share on other sites
polo6n2g40

now i had the new hubs, i could fit the brakes and driveshafts

gti 8v vw2's

nozmk220vt11212001.jpg

nozmk220vt11212003.jpg

16v mk2 hubs, 280mm 2 piece discs, S2 calipers and braided lines

nozmk220vt11212004.jpg

nozmk220vt11212002.jpg

re mounted the second horn from the grill with the other one in the inner arch

nozmk220vt11212005.jpg

and refitted the front bumper

nozmk220vt11212006.jpg

i sorted 95% of the loom, it turns over and we have spark and fuel injectors are firing but no inlet mani so not able to start.

waiting on a few more parts and the bits back from the ally welder and should nearly be there :-D

Share this post


Link to post
Share on other sites
NOZ

Then the disgusting grey bumpers need to be resprayed!

Share this post


Link to post
Share on other sites
polo6n2g40

:lol: new bumper i think bud

not a lot i can do now while waiting for parts and the bits back from the ally welder

i trimmed 10mm out of the tip and repositioned the alarm siren

nozmk220vt21212001.jpg

and made a bracket to hold the filter in place

nozmk220vt21212002.jpg

modified and fitted mk4 starter loom channel

nozmk220vt21212012.jpg

also decided i'd trim 20mm out of the power steering res bracket

nozmk220vt21212003.jpg

nozmk220vt21212004.jpg

nozmk220vt21212006.jpg

nozmk220vt21212007.jpg

then i remembered i had to run the loom for the sub / amp and HID relay, i decided 4 wires on to the + terminal was too much so went to my spares cupboard and got a mk4 battery fuse box

nozmk220vt21212008.jpg

nozmk220vt21212009.jpg

i decided to make a cover to hide the last bits of HID loom next to the battery

nozmk220vt21212010.jpg

nozmk220vt21212011.jpg

i also fitted new fan switch, trimmed a couple of lugs off the rad and moved it in the last couple of mm to give more room for the boost pipe

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now

  • Recently Browsing   0 members

    No registered users viewing this page.

×
×
  • Create New...

Important Information

We have placed cookies on your device to help make this website better. You can adjust your cookie settings, otherwise we'll assume you're okay to continue. Terms of Use Privacy Policy Guidelines