1981 Rabbit L 1.6D

[akrallysport]

After enjoying life as a Subaru owner, I decided I needed a more economical ride... and found this:

1981 Rabbit L 1.6D 5-sp w/ <50k kms on rebuilt head, solid floors and shock towers

To-do:
- new WP gaskets (urgent), t-stat, hoses (as a precaution)
- shifter linkage bushings
- left/right engine mounts
- quick suspension/brake inspection

Goals:
- full repaint
- turbo (using many of my AAZ parts sitting in some boxes in the garage and some IC work)
- interior removal and update (replaced with sportier seats, cabby center console with gauges, etc.)
- damper/spring/suspension reinforcement

[ORCoaster]

Oh yeah, OH YEAH,  you are going to love that 2 door.  Yank the back seat and put down a 3/4 inch thick piece of plywood with a cutout for the spare.  Carpet goes all the way up to the foot wells and you have a very nice mini SUV.  I haul all sorts of stuff with mine but I did need to raise the springs in the rear after I loaded it up with 11 gallons of Veg Oil.  Why burn the expensive stuff? 

Only one question.  Did they charge you extra for all the green slime on it?  Crazy how folks don't clean a vehicle before selling it.  I knock the price offer when they do that. 

And now that you own one of these critters all free time will now be spent on it.  Trust me. 

Mine got a cruise control install start on it today. 

[gtiguy1994]

Nice! What color interior is that? Lipstick red? Royal red?

[ORCoaster]

Looks like the VW tan to me.

[akrallysport]

Very red. 

[ORCoaster]

Nicely weathered.  Let the Mods begin.  Seats first.  Gotta be comfortable every mile.  Ricaro rules.

[tyb525]

Let me know if you wanna get rid of that 5-speed

[akrallysport]

Engine and trans are out... trust me, you don't want it. Diff bearings have taken a vacation, destroying the output seals... this explains why the engine smells like gear oil. This just gives me the opportunity to revise my plans. As I still have my 020 from the AAZ with a <10k km clutch/flywheel, an upgrade is in the works. Now I just have to figure out if the current axles will accept 100mm inner CVs or if I should swap over the 90mm flanges. I do want to split the trans from the AAZ in order to install a new main gasket to not have any issues with tech inspections at auto-x events.

Andris

Pics for clicks...

[tyb525]

Looks like the vacuum pump has been upgraded.

[akrallysport]

I believe it has... looks identical the one from my AAZ kicking around. Did a quick test fit of the turbo and manifolds after degunking the the backside of the block with some diesel and elbow grease. Working overtime at work tomorrow, so progress will come on Sunday when I pick up a 1.6TD intake manifold in order to match the port shapes.

[akrallysport]

A lack of updates usually means I'm busy... and having a cool boss that gives me free reign of the shop during lunch breaks gives me reason to be busy, especially when the sandblast cabinet is part of the deal. As a result many items have been sandblasted and repainted with the exception of the chassis itself.

- engine bay painted in racecar (generic rattle can) white
- steering rack repacked and installed
- new tierods installed
- pedals sandblasted, repainted, reassembled and installed
- purchased used (low mileage) set of Bilsteins and lowering springs (to be cleaned up)
- rear axle completely rebuilt
- poly bushings installed
- new front control arms (w/poly)
- drilled, tapped manifold to install EGT probe
- intake/exhaust manifolds finalized/installed
- new engine mounts (brackets blasted and painted)
- installed new brake booster
- purchased used Corbeau FX1 seat

to do:
- new rear main engine seal/gasket
- trans main seal
- convert mk3 AAZ trans to 90mm flanges
- install clutch and assemble engine/trans (+timing belt at this point)
- finalize turbo oil feed and return lines (weld appropriate fittings for oil pan)
- install rear axle & suspension
- install front suspension
- install MC and new brake lines AtoZ, bleed brakes
- design and manufacture lower front susp brace and driver's seat brackets
install engine
- install wiring loom
- interior... everything
- fabricate custom exhaust

My goal is to have it done by Aug 23-24 with a couple of weeks of shakedown before my first autocross Sept 7.

Pics to come tmw.

[icyhotpatch]

Its August 30th is it done yet?

[8v-of-fury]

I wish I had the ability to strip it down fully.. I am considering picking up a cheap HONDA in the mean time so I still have a daily! haha

[icyhotpatch]

No bad 8v thats what the people at tdi club said I should consider and it was horrible. That is unless its an 80s honda wagon with awd. Those are cool.

[akrallysport]

I'm happy to see people take an interest in it... long story short, no it's not done, but I'm pushing like mad so that I can get it done before the craziness starts in terms of schoolwork (final-ish year in Mech Eng).

And here's the long story:
Probably the worst month of motoring, EVER. On my way to work Aug 12 (keeping in mind that I just drove home from the cottage the night before) my Subaru decided to lunch on its timing belt. Pretty much the worst case scenario applies here... accelerating in the left lane of a 4-lane highway, but I managed to coast it off the highway. Engine is toast and the car has to be parted out before the snow flies. After missing out on 3 or 4 decent diesels I decided to bite the bullet and bought a 95 BMW 525i w/5sp... got it for a steal, took care of the maintenance/small problems and was driving like a dream until the notorious BMW cooling system reared its head and sheared the upper rad hose from the end tank of the radiator. Fingers are crossed regarding additional damage in the form of a head gasket or warped components. So I now own 3 cars, none of which run but parts are coming in tomorrow for the Bimmer and should have it back on the road by Thursday.

As for the Rabbit:
- Solved the drive flange problem, in theory. Ordered a set of Scirocco axles with 100mm flanges.
- Suspension & brakes are done... just needs an alignment.
- Engine is in, but still working on some cooling lines and oil lines
- Currently fabricating the exhaust (2.25in downpipe, high flow cat into 2.25 exit with turndown... still not sure if I'm going to put a muffler)
- Currently working out the wiring to have a hatch mounted battery for better weight distribution.
A couple of other small bits remain but listing those would be tedious...

Took some measurements to make a rough exhaust design: