Mk2 GTi Syncro Build - Operation MOT

It’s definitely not wider at the rails, but bulkhead up to the seat rails it looks wider.

that’s what I’m planning, without the Rallye tunnel. I’ve cut above the rails and will make it fit back on

 

It’s wiring time! I need to splice T14a into the loom and then splice the plug end of the loom into the Mk2 loom. Easy, right?

Mk4 loom, just need to finish the brown plug, now I know where it’s going. So can splice and extend.



Then pop this lot into the loom.


Edit*

T14a is now friends with the CE1 loom

 

Big day today!

Started the day with a bit of rust repair,





Usual stuff there, nothing special.

Removed the fuel tank filler thing, because it won’t be needed with the fuel cell that’ll be fitted.



Then onto the fun stuff.



Measured up a cross beam,



Diff bracket welded up.



Then some supports fitted and tacked into place, then fully welded.

The diff is now mounted, I’m going to add more support and build a structure around it, a place for the battery and then a frame for the fuel cell but that’ll be done at a later date.



Front fitted.



Rear fitted.



Touch down!!! i wanted to get the engine and gearbox in, prop fitted but we couldn’t find the rear engine bracket dad said he had



One day they’ll be useable!!



Its super slammed at the moment, the coil overs need winding right up. But it rolls around, which is nice!!

 

ah okay, I didn’t think of using that tunnel. Like I say, I’m just going to wing it and build it as I go.

I’ll either get a carpet made up or make one up myself, it can’t be that difficult?

Oh really? Is that due to the arms you made? I saw those in the thread.

 

Yeah I looked at bolting a TT on but it would have been too much work to keep it as OEM as possible. Then this lot came up, which was nice.

I’ll have a look into it, might be worth a go.

 

Well we are back to wiring, sadly!

Thought I’d start cleaning up my engine loom.



The start!





Then new plugs and wiring
And we are done!

 

you know you can get a complete coilpack repair harness for that, includes plugs and everything. no point patching up the old stuff it'll just keep on cracking
https://www.awesomegti.com/shop-by-...m-replacement-for-cars-with-oil-level-sensor/

 

Yeah I know but that’s £50, that I don’t really want to spend. I replaced most of it anyway as it was all broken. I’ll just keep replacing it for free until it’s all gone

it’ll keep my busy, at least that’s what I’ll tell myself.

 

Well not a massive day today, but having my daughter around makes it a little harder to focus.

We took the transfer box off the gearbox and found this. So I’ll have to weld that back on. Being cast, that’ll be fun! Lots of heat required!!




But managed to get the gearbox and transfer box on, after a lot of grinding, we managed to make it fit.


Lots of grinding later and tadaaa

One crushed finger Later and she’s in!


It’s tight down there!!



Then we ran into a problem.



my rubber joint seems to be 10mm bigger across the holes, but part number marries up with a mates and his is 90mm. So I assume mine is just knackered.

That didn’t stop me though.

More cut for clearance.



Then start of the bracket.



Got the drum plates off and a disc on, now to find some carriers, as I assume they are NLA.

and this is where she’ll lay, for now. The most it’ll look like a car for a long time.

 

syncro carriers are 191615425A and 426, TRW part number BDA228 BDA229. showing NLA everywhere so its ebay.de for you!

'syncro brems hinten'
https://www.ebay.de/itm/264690670905

 

I found the part numbers on Etka but couldn’t see if they are NLA so thanks for confirming.

This is going to be ‘fun’

I’ll get making!!

 

A little more today, not a huge amount.

Prop is now in, and running night and straight.



First job, start a downpipe so tunnel back in, at desired height, although this is my only picture.


I used some steel rod to just hold it up for the mean time, I need to order some sheet metal to create a butt strap.

then onto the DP. there’s not much room!!







It’s tight, this is just rough mock up so far. So don’t criticise my cuts and tacking, I’ll cut it all nicely and properly weld it up when the time comes.



Tight! But nothing touches.



Top view.

and here is the rough shape. I’ll obviously cut it properly and weld it up. But I know it will fit now. So that’s good.





Then onto my mock up fuel cell, one I was planning on buying is a tad too big. So will have to find another, or get one made.



then started with a boot floor structure.



but I didn’t get too far with it. I packed up shortly after that.

 

And a big thank you to Eddie for my roller wheels, it’s much easier to push around on wheels that actually fit!

 

the other thing about the syncro/mk3/corrado tunnel is the opening is a bit wider to the engine bay so it gives you that bit more space for your downpipe, something to bear in mind if it gets a little too tight. is a bit of a bashed in section right where the downpipe needs to go, heres corrado:


vs mk2:

 

Yeah, I’ve got a bit of wiggle room and I’ve got a bit of metal work to do, it’s fine. We’ve got space! If not, we’ll make space

 

nothing a large hammer couldnt fix for you