Driver, to 16 valver, 2017 rebuild!

This is the long term build for my Mk1, I'm in the process of updating the thread and editing some of what I originally wrote, (alot of it made me laugh now I'm a bit older!)

I've had my mk1 since I was 18 (2004), brought with some birthday money for £500 from Stroud in Gloucester, my dad drove it home while my mum drove me back in her car. Many comments on it having poor brakes from my dad, which I would soon grow used to. The car was found by a very good family friend who used to work for Autotrader taking photos for the magazine, (remember those days!) He overheard a guy talking about it in a petrol station in Stroud and mentioned I would be interested. Unfortunately he passed away a few years back, and this has made my mk1 even more special to me.

It was originally a white 1300 driver, but I never took any photos of when I brought it back…

From 2004 to 2006 I carried out some welding and had it painted Mars red (apart from the bay) ran FK collies and R10 ronal turbos, and a Peco big bore 4! It was my first car and daily driver. I never used it as much as I should have because I was either hungover on the weekends or too worried about leaving it anywhere!

The car was then off the road for a year or so, when I had a standard mk3 cl (the only car I've ever sold!) and then my mk2 8v 90 spec gti, (current on a roll over jig..)

The below photo is around 2008, and the start of my 16v conversion - Of course I thought I would have it up and running in a year

The donar, 87 mk2 16v gti


Getting the lump out





Last shot with my trusty 1300 lump


1300 on it's way out, Note home made engine hoist on wheels  

1300 out,


Cue cheesy pose with engine…, note home made engine crane, fully mobile on casters









Cleaning off the muck, ready for welding then paint


Stripping the 16v head

Taking the valves out etc, with my modified compressor tool
 

Cams, tappets, etc out


The bottom end in pieces

Stripping it down on the stand


Crank, great having the engine stand for this

Crank out, I've sized the journals, and there is minimal wear, so gonna order the standard bearings etc


Next up is re welding the engine mount and a few other bits, then get some paint in the bay, the engine has been sent away to the machine shop, so waiting to get that back to.

Will keep you updated

Hope you like Cheers

Pete

that engine hoist is ace mate   so is the car ,keep us updated

yep,really interested in this one!
keep up the good work,
will be watchin!!

looks good! lovin the mandatory haynes mk1 mug on your roll cab!   :wink:

going to be good, top work fella impressed , i wish i was that organised, those bits would have been kicked allover by cats or kids by now at my house.

Cheers for the replys, ive got the block and head back now and ive finished welding in the bay, so will have some pics up soon

bigdave said

looks good! lovin the mandatory haynes mk1 mug on your roll cab!   :wink:

Gotta hav me brews in my mk1 mug

Thanks for looking

Pete

Sorry if you've already seen this on ed38, as im posting the same thread on here to.

I have some more pics of the progress so far…

Cut the rubbish riveted in plate repair to weld in a plate


Made a template out of card




Welded this in, with another smaller plate on top to strengthen it more, was a pain to weld the first plate in, it kept blowing thro', but got there in the end, not the tidyist job, but it will do the job.


Then on to the drivers side engine mount, cut the old one off, using spot weld drill which i broke, then used normal drills and brute force


Straightened the mount out, and bent it to fit in its new position


Then welded it in


Also put some patches in where the splitter mounts to the frontpanel.



Also welded up where the mount used to be as i had made a hole


Picked up a gti steering rack, thank you mark


Then i picked my block and head etc from a local company.
Block has had it top face skimmed, and has been re-bored to +.5mm, over standard (81mm is standard), so there is plenty of meat left on the liners if anything goes wrong, oh and cleaned and painted, tho i will paint it red.




Cylinder head pressure tested, skimmed, and valve guides checked over.


Crank had the journals polished just to take the oil marks out, as the wear was minimal.


All new bearings, thrust washers, and pistons to suit.


The new pistons


Also have all gaskets, seals, oil stem seals etc.

At the moment im prepping the bay ready for paint, so will update soon.

Cheers for looking

Pete

very nice, be good to see it when its finished, i wish i had a garage to do this sort of thing

Nice, ill be doing that very soon.

Coming on well Pete.

Have you managed to get hold of the other gear linkage parts?

Whats the next job,building up the engine?

Cheers for the replys ppl

mark83 said

Coming on well Pete.

Have you managed to get hold of the other gear linkage parts?

Whats the next job,building up the engine?

I may have some bits lined up but still looking at the mo, plus i have some Q's for you :scratch:

The next job is prepping the bay and spraying it, then on to rebuilding the engine which should be fun

Im thinking of putting the ecu inside so need to sort that out also.

Pete

Very good work so far - reminds me of my 16V engine rebuild! I never did the bottom end though. ECU? You can run the 16V very successfully (good power) using the K-Jet stuff from the Mk2 Golf 16V (which I'm assuming you already have), if you used an ECU you'd need to use different fuel injectors too - the ABF fuel rail would be the obvious choice, unsure if you'd need to use the entire head or simply transfer the fuel rail and a couple of other bits from it.

Keep up the good work.

doing this very same thing myself at the moment..
i,m very glad you've the patience to not only carry out the task
but to document it too!!

you mentioned gti rack and some gear linkage parts, am i missing something??
still waiting on my box turning up so dont know what i need yet?
i,d better find a rack too if necessary!

looking great though buddy!! keeping a close eye on this thread!!

cubed said

doing this very same thing myself at the moment..
i,m very glad you've the patience to not only carry out the task
but to document it too!!

you mentioned gti rack and some gear linkage parts, am i missing something??
still waiting on my box turning up so dont know what i need yet?
i,d better find a rack too if necessary!

looking great though buddy!! keeping a close eye on this thread!!

Yea im using the gti rack and gear linkage bit as my mk1 is/ was a 1.3, so the gear linkages are different 4 speed to 5 speed, and they also mount onto the rack which the gti rack has a mount for, and the small block rack doesn't.

Just search thr'o the many build threads here, and on other site like club gti, your soon get list of parts up.

Paul C, i will be using k jet, by ecu i meant the kjet ecu thingie.

Pete

I assume you mean the 16V's ignition ECU? There's no value putting the ECU inside, it sits nicely in the scuttle tray and the wires for the coil and TCI are all there.

looking good, im hoping to do this to my 1.1. wish i had the know how to do it myself tho. does the petrol tank and fuel stuff have to be changed? would be good if you could put me in the right direction for the parts etc, would be a great help! d'ya reckon i get a donor car? ive seen a cheap mk1 1.8 16v only 300 quid! rob

You could get a donar, the mk2 donar was good cus i could see how it all work together when looking at the kjet injection system and the wiring. If you where using carbs it might not matter so much.

I need to sort the fueling stuff soon, as far as know yet i will need,
Cab lift pump, for the 1.3 fuel tank, (as it's not a gti tank)
mk1 pump and accumlator, and the pressurized mk1 fuel filter
Various pipes, and some home made mounts
Oh and fuel lines, still undecided here, may have custom ones made up, as metering head is the other side to a mk1 gti setup, so don't wont to cut up a brand new set of lines up.

So much more to do :roll:

Pete

paul_c said

I assume you mean the 16V's ignition ECU? There's no value putting the ECU inside, it sits nicely in the scuttle tray and the wires for the coil and TCI are all there.

Yes thats the one, was going to look at putting it inside to tidy things up, but if it's a pain to do i wont.

Pete

good work mate this is my plan with my mk1 convertable when ive finished my mk2 vr6 kep an eye on your progress.

Will have some more progress soon, just prepping the bay is taking a while, in between collage work. God only knows how much work these totaly smoothed bays take 8O