MK1 GTI 1.8T 20v 25 Year Project

What springs and struts are you using

 

I'm running Gaz Gold on mine with 6" springs

 

New M10 alternator Adjustable Turnbuckle fitted





GRP Bonnet for the 2015 Season ready for paint (Lhasa Green)

38mm Vents drilled to prevent heat soak and aid TB Air flow.

 

The time has come to upgrade the gearbox so my beloved 020 Box is up for sale.

Great box served me very well
http://www.clubgti.com/showthread.p...fe-LSD-Sachs-Sporting-Clutch-Lighten-Flywheel

My Great 020 ACD Code Gearbox
3.94 Final Drive Fitted
Quaife Limited Slip Diff

Ratios - 1st 3.45 , 2nd 2.12 , 3rd 1.44, 4th 1.13, 5th 0.89

100mm Drive Flanges

Sachs Sporting Pressure Plate
Helix Ceramic 4 puk friction plate
Lighten & Balanced Flywheel


Modified Flywheel



SACHS Heavy Duty Pressure plate for the Helix Ceramic 4 PUK



Sachs HD pressure plate, Helix 4 Puk ceramic paddle and lightened Hotgolf Flywheel.






020 Gearbox 3.94 final drive & Quaiffe LSD , TSR Linages, short shift & weighted shift ready to go in too.




I'm upgrading to an 02J DZL V5 Box with 4 Pot bell housing fitted and Gripper Diff , i'll keep you posted on progress

 

Got the new Gearbox

02J - DZL Bora V5 BOX so need to change the Bell House Casing for a 4 pot one .

The Ratio's are spot on though so worth the extra work

Final Drive - 3.94
1st - 3.30
2nd - 1.944
3nd - 1.308
4th - 1.029
5th - 0.87 (won't be using on the strip)

Also got a New Quaife Diff on the Way

 

Update -

Gearbox all rebuilt final spec - DZL internals , Peloquin's LSD , ARP Diff bolts

Final Drive - 3.94
1st - 3.30
2nd - 1.944
3nd - 1.308
4th - 1.029
5th - 0.87

clutch release fork modified with welded in plates








5kg Hotgolf Lightened Flywheel



6 PUK Clutch plate


Peloquin's Diff




02A Casing Fitted




The finished Gearbox ready for fitting Tonight

cable clutch release fitted and Rod Change gear system for the 02A/02J

 

Why did you fit the 02a casing to the 02j?

Interested as my dad is hoping to fit a 02j to his mk1 16v.

 

The 02J was a DZL Code from a Bora V5 ( Different bell housing on V5 & VR6 )

The DZL Ratio's were exactly what I wanted.

 

Ok understand.
We have sourced a 02j from a non turbo 20v a3 which has given us the ratios we need.

Sorry for the questions.
I think iv missed it but what gearbox mounts did you use?
What drive shafts/CV/hub/upright have you used? (I assume 100mm stuff?)
What shifter?
Hydraulic clutch conversion?
Is that an off that shelf clutch?

 

02A 100mm flanges

Cable Clutch Actuator (SEAT) from Holland
https://www.bolt-action.nl/product/vw-02a-cable-clutch-actuator/

Bolt Action 02A Rod Change Conversion from Holland

https://www.bolt-action.nl/product/mk1-02a-cable-to-rod-shift-conversion-stainless-steel/

XKD Stage 3 6 PUK clutch from USA

EPYTEC Engine Mounts
https://www.bolt-action.nl/product/vw-mk1-02a-gearbox-mounts/

 

What dictated your choice of LSD please ?

 

My Friend James Hodson uses the Peloquin's Diff and has had great results over the last 7 years so that made me decide on this types

my Gearbox man did comment and was impressed with the diff and the ARP bolt's I supplied for fitting .

I was thinking of going for the Gripper plate diff at one point but didn't know anybody using one .

 

Thanks for the feedback ... in time - I would be interested in how it performs vs. the Quaife

 

Gearbox all fitted , I also made a modification to the Rod Shift Kit were the linkages connects to the vertical movement pivot . the original bolted straight to the OEM Bracket but the shift was stiff .

As you can see I have added a extended section which gives more leverage and a smoother shift .

The rod shift is all complete and the shift is very smooth and direct.

 

Update -

Clutch cable was too short , thought it was too much of a struggle to get it on.

so extended it with an M6 Rod coupler and 2 locking nuts.




Extended works perfect total cost (25p)



All finished

 

Looking Good Richard, looking forward to chasing you down the strip next year

 

Great read pal [emoji106]


Sent from my iPhone using Tapatalk

 

Love the inlet trumpets etc
Jon

 

Update -

Everything is ready for the 2015 season but now looking further forward and the Turbo Project is starting to gather speed .


Looking for a manufacturer of a Tubular Manifold with top mounted T4 Twin scroll twin 38mm Waste gate Flanges.

The Turbo Engine will be the same capacity 2036cc 16v with lower compression 8.5 : 1 JE Pistons
20v Turbo Inlet manifold custom made same as Toytec's to a 16v bottom flange.
final spec has to be finalised but will also be looking at the following .
Megasquirt MS1 V3
Coil on Plug Coil packs
RC 1000cc injectors

 

Update

Drove the MK1 for first time with new Gearbox set up , the engine feels a lot better balanced with the 02J and lightened 228mm flywheel compared to the old 020 set up.

Also updated the Megasquirt software on my tablet , very impressed with the update and works great with the Bluetooth dongle

just waiting for Fibreglass bonnet and tailgate back from paint shop