Mk1 Golf conversion to VNT diesel power

[regcheeseman]

Seeing as I'm detailing other bitts of this project elsewhere on here, some may be interested in the intended recipient...

Started out as a 1983 1300cc mk1 Golf Driver


Taken home and stripped out


Rolled and bits restored



Notched chassis rails to slam it.


Vinegar soaked and 'rustbuster' epoxy masticed


Starting to remove seam sealer and attack rust


Get 'em started young


lots and lots and lots of holes welded up, seams welded paint stripped

[745 turbogreasel]

Nothing cleans like a lot of paint!

[regcheeseman]

Big hole cut out


Big hole filled - note RHD car now has direct action brake servo (a big one too)


More epoxy mastic


Filler


more paint


Not happy with the slam panel - so plated that as well.


All wiring hidden under wing


Tidied


Modified my ebay cheapy IC with a simple stencil  


Breaks cover for a quick photocall


Home made wheels - spot the mistake?  

[rallydiesel]

I've gotta get me a Rabbit. I'm jealous of your build.

As for the wheels, is the channel too far in the centre of the barrel? Would that make it difficult to get the tire on?

[rabbitman]

Wow that's nice , how long did it take to get to that point?

What coilovers are those?

I like the wiring job, it always bugged me how they run right across the engine bay.

What's that bottle under the left fender?

Nice work, keep it up

[regcheeseman]

As for the wheels, is the channel too far in the centre of the barrel? Would that make it difficult to get the tire on?

Difficult? - No, impossible. 

What coilovers are those?

Ebay cheapys that came still wrapped in a box in the back of the car.

What's that bottle under the left fender?

I could lie and say water injection - but in reality, I messed up. 
It was due to be an expansion/overflow for the radiator - I'd assumed the top fill rad had an overflow at atmospheric pressure like a motorbike setup - it doesn't so the bottle is now removed and sat in the garage cupboard.

[regcheeseman]

Few more pictures of progress

Rear end


Front end, my IC fun wasn't completely wasted. Shame about the dog poo bags!


One manky gearbox tidied up


Block well on the way (WAITING FOR GIRDLE!!!!!)


Marked up the manifolds for some port matching and a bit of flow work.


Finally - toys. mmmmwahahahahahahahahahahaha!

1Y/AAZ head, 1Y manifold, MK4 VNT turbo, MLS gasket, ARP studs

[Turbinepowered]

Wonder how long that's all going to stay white.... 

Lookin good!

[regcheeseman]

Ok, I'd forgotten the thread so by way of a little update....

Wonder how long that's all going to stay white....

Not long....


The more I looked at the white and black the more I disliked it.

knocked myself a pump together out of a few old pumps, few hours of swearing, and fiddly assembly.



Lot's of cleaning, rubbing down, spraying, polishing to get to this stage

It's AAZ based, got a 10mm head from a TDI (up from 8mm), running on the AAZ camplate and set up with 1.10 mm lift.
It's got a GTD boost pin and spring, gov mod and aaz limiter blanked off.

Started to put he headlining in, ignored advice and did it my usual way, fitted the back, pulled the front taut and glued that, held nicely by bulldog clips bought from staples. Then did the side, I'm well happy, no creases or sags.


made some custom rear 'door' cards


painted my inlet manifold.


Got dish?


Had to push the Golf out into the sun, the calipers are on, maybe a bit 'barry' but I like them


My boy was straight in it, cool kid.


And the rear end just gets better with fat rubber to beef it up


Engine going in next week 

[regcheeseman]

A few more hours work and the motor is off the stand and ready to go in.

Red clutch should give me at least another 20 brake.

[regcheeseman]

My sketchy 20 year old engine hoist got put into use, this was bought by my cheapskate parents from god knows where (£1 shop?) and is actually sold as an engine hoist. It consists of a a few tiny pulleys and some worn looking thin cord.
However, as it's done many times before, it lifted a motor and gearbox in.


After a few minutes faffing the first mounting bolt slipped home and the gearbox mount temporarily made with some webbing. The hoist can be removed


All is not sweetness and light, the oh so easy gearbox mount is 55mm away from where it should be so it's back to plan A - make it from worthing caddy's pattern.


And the alt fouls the oil cooler by about 3mm. so that has to be cut out. 

[Grey_Smoke]

WOW, that engine bay looks good!!!!!!  eh, scrap good, it look amazing!!

[rallydiesel]

Looks great.

[regcheeseman]

My turbo VNT linkage has been modified to suit the bowden cable operation.



Not happy with the arrangement for the sensors, so I went and bought some decent tees in the right size.

Finished the first stage of the exhaust, just got to add the hangers and tidy it up a bit.

2.5" from turbo to rear beam (and potential for a straight through side exit pipe )
And then a 2" system and token silencer box and discreet turndown exit

All in stainless, the manky bit is an pre-used section cut from an old downpipe but it'll clean up like the rest

Bored of waiting for bits to turn up and needing to get into the loft I had to take the car off the stack of blocks it's sat on for 2 weeks and get it out of the garage.

Certainly sits a bit better with some weight in the front


With the loft sorted and rain threatening I tried to push the car away again. (here's where I start collecting scene points by the bucketload)


It wont go back in the garage, the less than 2" tall step up is whacking the sump, I ended up fashioning ramps to put it away.



Exhaust is finished and wrapped, had to make a bracket to keep the gearchange cables out the way.
Wired the turbo sensors, made the cables for the VNT
Fitted the spangly new clutch hose - thanks to http://www.helcarkits.co.uk/

[rallydiesel]

I love it all!