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Author Topic: 1991 VW Golf GTD intercooler  (Read 260 times)

May 20, 2018, 02:43:00 pm

Ice_ken

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1991 VW Golf GTD intercooler
« on: May 20, 2018, 02:43:00 pm »
Hi guys, i'm new on vwdiesel.net but i've been into vw's for about 10 years now.

My first car was a golf mk2 GTI, i've had it for about 10 years now and fully restored it. Secondly I've bought a mk2 GTD, as a daily.

Bought in august 2013, I was working at a VW dealership at the time:


Gradually I started fixing it up as a low cost project; fixing the fog lights, giving it a polish, lot's of touch up paint, new interior, restored the heaterbox, bought wheels, lowering, painted the roof and hood etc etc, she was looking good and OEM:


it then got stolen... :o



1991 VW GOLF GTD IC
1987 VW GOLF GTI
2010 RENAULT CLIO RS 200
2015 BMW S1000R

Reply #1May 20, 2018, 03:01:50 pm

Ice_ken

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Re: 1991 VW Golf GTD intercooler
« Reply #1 on: May 20, 2018, 03:01:50 pm »
However through sheer luck the cops found it 2 days later, damaged and abused, partly disassembled...


this is part of the roof that got painted 2 week before:


I then found some sebring wheels, which I had sandblasted and painted myself:


Radio got stolen so found this as a replacement, looks pretty period correct. And yes, boostgauge...


Hood got scratched aswell and got repainted, so picture of the engine:


It was looking pretty decent now:





« Last Edit: May 20, 2018, 03:05:06 pm by Ice_ken »
1991 VW GOLF GTD IC
1987 VW GOLF GTI
2010 RENAULT CLIO RS 200
2015 BMW S1000R

Reply #2May 20, 2018, 03:12:19 pm

Ice_ken

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Re: 1991 VW Golf GTD intercooler
« Reply #2 on: May 20, 2018, 03:12:19 pm »
Found a perfect GTI windscreen so replaced my scratched one:






at this point the headgasket failed (340 000km).

So a donor car(low mileage, OE replacement engine at 100k) was bought for the AAZ swap:


the engine was taken out of the Seat


and a new project was started...

1991 VW GOLF GTD IC
1987 VW GOLF GTI
2010 RENAULT CLIO RS 200
2015 BMW S1000R

Reply #3May 20, 2018, 03:32:12 pm

Ice_ken

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Re: 1991 VW Golf GTD intercooler
« Reply #3 on: May 20, 2018, 03:32:12 pm »
The GTD was stripped for engine replacement:


cleaning it up, degrease, derust,prime, paint, repeat:




So I put new stuff in it, 22mm masterbrakecylinder, new coolantreservoir, new dieselfilter, PAS bracket. Also did some wiring, moded the coolant reservoirbracket so the wiechers strut bar would fit.




Wiechers strut braces:


rebuild shift mechanism:


polybush fitting on new wishbones:




new clutch fitted on the aaz:


fitted the gearbox and a new starter:


made quit a bit of progress today, rebuild the subframe, new A-arms, all new bushings, shiftmechanism completely rebuild:




aligment of the shifter:


Wiechers brace in the trunk:


Engine in after loads of mods done to it:



-new turbo, OE KKK watercooled
-new crankpully
-new crankpullybolt
-new gaskets on intake/exhaust
-new belts
-dieselpump clocked
-custom oil return line
-some other minor things

KW suspension, PU bushes, PAS steering, ATE powerdiscs, ferodo DS2500 pads, rebuild calipers, all new endlinks etc etc






spent loads of time polishing and waxing
« Last Edit: May 20, 2018, 03:35:05 pm by Ice_ken »
1991 VW GOLF GTD IC
1987 VW GOLF GTI
2010 RENAULT CLIO RS 200
2015 BMW S1000R

Reply #4May 20, 2018, 03:43:14 pm

Ice_ken

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Re: 1991 VW Golf GTD intercooler
« Reply #4 on: May 20, 2018, 03:43:14 pm »
bought more parts




redid the frontclip, painted gloss black, new lock + catch, new stickers, bolts etc, nice and new.




Dynamatted the entire car, expensive but worth the money.


cars and coffee


got married in this car

1991 VW GOLF GTD IC
1987 VW GOLF GTI
2010 RENAULT CLIO RS 200
2015 BMW S1000R

Reply #5May 20, 2018, 03:56:27 pm

Ice_ken

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Re: 1991 VW Golf GTD intercooler
« Reply #5 on: May 20, 2018, 03:56:27 pm »
I then decided to fix some small rust issues, turned into a full respray and G60 exterior  ;D


















17" wheels:


more parts:












repaired and replaced the headliner:
1991 VW GOLF GTD IC
1987 VW GOLF GTI
2010 RENAULT CLIO RS 200
2015 BMW S1000R

Reply #6May 20, 2018, 04:08:51 pm

Ice_ken

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Re: 1991 VW Golf GTD intercooler
« Reply #6 on: May 20, 2018, 04:08:51 pm »
completed:













GTI exhaust:


more small pieces, attention to detail:




















oil change after break in:


new parcelshelf


Original splashshield for alternator belt inside the front grille:


new alternator and new wiring


votex console with vdo gauges; oil temp, oil pressure, boost and voltage.


@ meet up:





1991 VW GOLF GTD IC
1987 VW GOLF GTI
2010 RENAULT CLIO RS 200
2015 BMW S1000R

Reply #7May 20, 2018, 04:23:24 pm

Ice_ken

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Re: 1991 VW Golf GTD intercooler
« Reply #7 on: May 20, 2018, 04:23:24 pm »
enginebay fully complete:


not much boost for the moment:


wetsanded and polished:


Area where I live:


failed waterpump


clucthed pulley on the alternator and new waterpump


Mocal oilcooler:




went for G60 brakes rather then the 8V brakes:








Chapel of the muur @ Geraardsbergen, hometown. Cyclists will know this place:


version 2.0 clutched alternator pulley on a new alternator (failed bearings)


New Hella headlights:


new doorhandle, old one broke:


1991 VW GOLF GTD IC
1987 VW GOLF GTI
2010 RENAULT CLIO RS 200
2015 BMW S1000R

Reply #8May 20, 2018, 04:36:34 pm

Ice_ken

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Re: 1991 VW Golf GTD intercooler
« Reply #8 on: May 20, 2018, 04:36:34 pm »
The rear beam was still a stock one, drums and no anti roll bar...So decided to build a G60 one:

sandblasted and powdercoated:






new everything:


the spec:
-G60 axle
-girling 38 calipers
-G60/gti rear discs + OE brakepads
-brandnew everything, hardware, brakelines,...the whole lot.

OEM new grille:


New wheels, axle installed:




So as you might have noticed the car was without licenseplates on the last pictures...I stopped driving it about 3 years ago, I bought another VW to drive daily. Yes this was my daily for about 2 years.

So a few moths ago, I wanted to put the interior back to more or less OEM and get it back on the road...
leather G60 steering wheel, black high quality floormats, golfball shifter, OE radio.


passed technical inspection last friday after 3 years of sitting. Soon to be on the road again.
1991 VW GOLF GTD IC
1987 VW GOLF GTI
2010 RENAULT CLIO RS 200
2015 BMW S1000R

Reply #9May 26, 2018, 02:04:25 pm

DLF-VW

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Re: 1991 VW Golf GTD intercooler
« Reply #9 on: May 26, 2018, 02:04:25 pm »
Beautiful GTD!! Followed you on vortex.
79 Golf GTD
96 Golf GTD(TDI)

 

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