MK1 GTI 1.8T 20v 25 Year Project

Great looking stealth machine!

Can I just ask about the 944 Turbo wishbones, is it an easy enough fit and do they make a big difference?

Thanks

 

The Anti-roll bar mount requires fitting modification but they are more rigid and look better etc, won't rust.

 

nice idea on the 944 arms. i was considering this years ago but never did for a couple of reasons...

the arms contain integral ball joints and they need to be remachined if one goes. cost of a set of arms was 250 if i remember right and there was only one place i could find that did the remachining on them.

second issue is that the front wisbone mount with the bolt has to be modified as the porker wishbone is larger in dia. it's a slightly tricky, time consuming job, it would be made easier to do on an car with no engine as well. i.e. like yours is now!!


get that block painted up!

 

That's my next job this week

Done !


And everything fitted, just need all the internals now.

 

For an Update on the engine re-build check out my Thread

http://www.clubgti.com/forum/showthread.php?t=186028

Got my Hands on a 944 Turbo front wishbone to see what is required for the installation.

 

cant wait to see what it takes to fit those

 

Front chassis leg is the major one that needs modifications!

Anti roll bar mount too.

Need to find a N/S one first so i have a set

 

http://cgi.ebay.co.uk/PORSCHE-944-W...14&_trkparms=72:1683|66:2|65:12|39:1|240:1318

Any good?

 

No its off a 89 model and the one i got was off an 85 , would do the same job but different with the 25mm hole in it.

will see what else comes up no rush at the moment.

 

Well here's whats been going on with the egine build thread nearly finished now.
Update - FlyWheel

Well just an Update the pistons should arrive today, the Flywheel just arrived from Hotgolf ! Excellent bit of work.

New Modified Flywheel


New Modified Flywheel on the Left and Standard on the right.



Standard Flywheel Weight




New flywheel weight big weight loss.


SACHS Heavy Duty Pressure plate for the Helix Ceramic 4 PUK



JE 83.5MM Pistons 10.5 : 1 Comp





JE Pistons, Integrated Enegineering H - Beam and JE Pro Seal Ring Set.

ARP Main Cap Studs

ARP Head Studs

ARP Crank Studs


Wish i wasn't going on Holiday Tomorrow now! would have had it all assembled by next week otherwise.

 

Microsquirt & loom



If anyone requires a loom making up please PM me and i'll send you Andy's details.
Bare block

New Oil injectors


Fitted new Oil Injectors with require fettling to give crank clearance

New Main Bearings original VW


New ARP Main Cap Studs


All fitted

New Eurospec Crank inplace

Main Caps fitted

All nuts fitted to studs ready to the Torqued up to 60LB/FT


New pistons and Rods Assembled and ready for installation.

New Crank Oil seals fitted too

 

havn't had time to do anything last week but will be finishing the bottom end this week and fitting the head and hopefully drop it into the MK1.

 

Well time to get the bottom end complete and fitt the pistons.

JE Pistons come with very good instructions on the rings gap positions.





H-Beam rods fitted with ARP Studs 50lb/ft torque 3 times.

New Oil pump fitted.

Windage Tray fitted also.

Schrick Baffled sump fitted too.
Complete now all ready for the flywheel, clutch and Head.


ARP Studs fitted to hold the Crank and Sachs HD Pressure plate together.


Fit the 16v Head.

ARP Head Studs all fitted using ARP Thread Lube


1.9mm ABF Steel head gasket 83.5mm bore (1.5mm compressed)



Allstage Head Flowed and Ported



Cams lined TDC 11.2mm lift



Piper Cam Pulley will be set at 3Deg Retard.

New timing belt fitted

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



Hopefully will be complete for June.

 

Making progress now, just need to fit the new heat wrap to the exhaust that Nige gave me !
Just the rocker gasket to fit , and then drop the Engine into the MK1 before fitting everything else.


Euorspeed distributor blank fitted.



Could do with a new steel water pipe, the existing one is abit out of shape now, are these main dealer only ?

Can't decide wether to fit the Poly side mount insert ! had them for ten years and can't make my mind up.


Microsquirt ECU & Loom has been collected to.


The wiring is straight forward now, 2 x 12v feed, 12v switch feed, - Ground, Rev counter feed, boot loader, Fuel pump feed.

 

Exhaust heat wrapped




Moved the MK1 to get the engine is easier , and cleared the engine bay for the new engine and radiator. Alot of the existing wirng looms will disapear too.




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



Hopefully the Engine & Gearbox will be in Tomorrow.
Well had a busy night, got the Engine and Gearbox bolted in place.


Pulled the old K-Jet Loom out first to make room, its amazing how much room you have under the bonnet when yo get rid of the K-Jet.

Only two wires i'm not sure what to do with apart from that it all comes out.

Two cables are the Oil pressure warning senors.



What a struggle thou fitting it on your own !

 

Also got the Pace Radiator off Benny for the project, which is ideal for TB's


Radiator in position, Oil cooler will have to be moved to the N/S to clear the air flow to TB's


New water manifold fitted for new hose set up.

Also side hose flange fitted with Temp Stat Adaptor on it ready for water temp sonsor for the Microsquirt

Throttle cable fitted to check fitting and size.

TSR Gear Linkages put back on ready for action.

Started assembling the Throttle Bodies

First step is to drill and tap No4 for the vacum pipe for the Brake servo.







Next step fit the Injectors and the Fuel rails & TPS Switch fitted too.





Then fit the Trumpets , which it looks like are got to be tight under the bonnet.


Trial fit on the spare Head in the Workshop






Still waiting for FSE fuel pressure regulator to arrive so i can complete the installation.

and then get on with the wiring and Microsquirt ECU Mapping

 

Here's the new FSE Fuel Pressure Regulator that has arrived



Adjustable too

Here's all the New fuel line and clips to go with it.


Just fitted the Jenvey 45mm DTH Throttle bodies to the Engine.

Looks like they will just clear the Bonnett, don't know about Air filters though.





Then fuel lines connected, ready for filter and FPR fitting .



The throttle cable needs a spacer fitting to get a straight pull on the Throttle mechanism

The standard throttle cable fits fine



Throttle Cable bracket spacer arrived this morning cheeers Bill.


Mounted spacer


Throttle cable now lined up correctly


Fuel filter mounted using the Old Coil Bracket.


New Banjo fitting used for Fuel supply line from Filter to Injectors


Fuel Return Pipe



FPR Requires a bracket making


FPR Mounted and Fuel pipes connected





I am going to fabricate an alloy airbox to collect the intake air above the radiator and angle it upto the trumpets.


p.s. This thread may get moved to members motors section and added to my 1994 - 2009 Project.

 

Its nice to have so much room you get under the bonnet once you get rid of the Bosch K-Jet injection.

Before



After


Plus also working on the T4 2.4D project at the moment now that the company VW Tauran isn't been used for personnal use now, to save on Tax.

Bought it two months ago 84k on the clock owner had it from new so a good find and a good solid base for my campervan project to tow the MK1 to the events.



Its been Painted N/S & O/S just to tidy up a few battle scares, the BBS Monza 17's were fitted last week, and towbar fitted too.

It also had all the belts and filters changed last week at Jordy's Rocket's Repair Centre.

and this week the 55mm lowering springs will be fitted, and i need to get the Front Bullbar stripped ready for Re- powder coating.






The internal camper conversion goes in the first week in July in time for Bug Jam.

 

awesome build mate, always loved this car since i first saw it at squires. I think this is pretty much the engine build i would love if i could afford it.

 

Looking good Brookie. If I were you, I wouldn't fit the side engine mount inserts as they will rattle your teeth clean out!

Gurds