Mk1 conversion: 2.0 16v on R1 carbs..getting there slowly!

Well its about time I introduced my project:



Its a Campaign which i bought for ?150 in february, the car had been badly chavved but had a big front brake conversion, rear discs and full Goodridge hoses so it was a good start!

Since then ive been slowly (and cheaply) restoring and then converting it with a 9A passat lump, cable change gearbox and a quartet of Mikuni's finest carbs.

My last Mk1 was great, standard apart from a 2.0 8v 2E lump, janspeed manifold and TSR big front brakes:



Having sold that I now run a Mk2 8v GTI as my daily chariot, live in Newbury and work in Southampton so it knocks up 350miles/week without complaint:



The Campaign had an empty engine bay whic had been bady stripped and smoothed, no scuttle panel, battery tray or brake linkage and servo so i fiured id have some fun and fit the m/c on the drivers side to lose the infamous Mk1 pedal feel (my red one had typical brakes, liked slowing down, not happy stopping    )

As i have a welder i figured id make all the bits i needed: gearbox mounts, exhaust manifold, carb manifold and cage to keep the budget to an absolute minimum…im no expert but im keen!!


2.0 16v lump stripped and cleaned: its a 9a block and my old Mk2 16v KR head & cams and an O2a box (left over from the 2e engin from my red mk1 :wink


 
Made a jig to hold engine in car and knocked up a rear gearbox mount….


…and 'revised' the side mount


Engine bay with a coat of silver hammerite before adding some steel to strengthen the dodgy missing scuttle join, m/c placed to line up pedals


Chopped the flange off an Audi 6a manifold, picked up a random truck manifold for the large bore outer tube….


…and combined it with the old Mk1 downpipe and a spare Pug 106 exhaust
to make this. Not pretty but only cost a tenner  


Dropped the rear beam to weld up both sills and fitted some polybushes.


Stripped carbs and drilled out main jets to 1.8mm, reset mixture and added 3.5 turns per carb, should get it running…


New brake lines, carb manifold, radiator etc all fitted, just needs the 16v ecu wiring up and the R1 fuel pump plumbed in  


Fortunately my girlfriend 'demanded' i let her sand the roof recess on a freezing cold windy December day… ops:


The rear sunroof drains had totally rusted through and all 3 sides of the recess was fecked- this took ages to repair but it would have been a shame to lose the sunroof! It defo wont leak now  

Nice project you got going mate

Some great custom work there - I love it

How did you mount the carbs?

Looking good - I really like the engine mount and exhaust fabrication…

Rich

looking good there mate, a lot of effort going on there, Should go
really well with the 16v and carbs, bike carbs are the way forward for N/A.

and if you dont mind me asking do you have drawings or size's for the  gearbox mounts, and if you dont mind me asking how did you square engine
in the bay, as ive already made my engine mount, just trying to
square it off

But good luck with it mate 8)

Hey thanks for the nice comments peeps  

crazyquiff:
To fit the carbs i did a quick cad template from the factory manifold, the shape allows for the injector cutouts and the water flange. i got it laser cut in 10mm steel - a bit ott but defo wouldnt distort when welded!
I got two flanges cut in case i buggered the first manifold up so ive got a spare flange- if anyone wants to have a go at their own let me know!

I used the leftover tube from the exhaust manifold to knock up some stubs- this took a bit of trial and error to get the angles right but it worked out fine. The R1 carbs spacing is nothing like the vw ports so i used four 1" lengths of tube to make a jig matching the carbs and then joined the gaps with tubes of various angles, flattening the engine ends to match the inlet flange…there have been prettier fabrications but few as cheap or as satisfying  


I picked up my R1 carbs without the inlet rubbers so ive used some fuel/oil resistant hose from Europa Car Spares (kit car specialists) to join the carbs to the inlet- unlined silicone hose apparently deteriorates.
Brake servo vacuum runs from inlet #1, it should actually be pointing upwards as i forgot about the alternator bracket when i positioned it… some 'minor' adjustment to the alternator bracket soon fixed that!


MickC:
I didnt do any drawings for the mounts, i found various pics of other conversion mounts and used these to get my head round the design: i feel sorry for people without their own welder! ?250 for some bits of steel 8O  Measured the gearbox bolt spacings and tacked the mounts together and to get my head round the layout I made a jig for the engine from some 25mm box and some thick threaded bar/nuts:

The engine was bolted at the front mount and then i adjusted it to fit side-side and fore-aft. Ive since modded my side gearbox mount with a bracket to locate the 02A clutch cable, sort of shown in this pic:

If you want some bracket dimensions let me know- i could always post up a dwg  :wink:



Todays progress:


I added a crossbrace to the cage- for this project i wanted to keep the interior but have a go at my own rollcage, it fits either side of the rear seat and doubles as a strut brace. For some stupid reason i want to keep the rear seat useable so the triangulation tube from the top of the drivers side to the rear is gonna be removable!!  :?


Trying to get my head round the wiring- not only have i got to wire in the KR ecu into the ignition loom but my clocks are from a late Scirrocco and have twin plugs rather than the single plug on the Golf loom…

Found something useful though- when i took the plugs apart i found that VW have helpfully labelled the printed circuit:

The MFA and fuel economy/shiftlight were never gonna work using carbs so all i need from the dash is a working rev counter, fuel gauge, temp gauge, dash lights, indicators, highbeam, battery and oil light.
Finally got my head round the crazy vw diagrams, also fixed the wires i had to cut to remove the old alarm.


Although its a shame to butcher some (probably) rare Scirrocco clocks I cant be arsed to go through the hassle of flogging them and buying some Mk1 clocks instead. I sold the Campaign mfa clocks & stalk when i got the car thinking id pick up a set of non-mfa ones- i bought the Scirrocco ones as i quite like the round dials, sods law meant they too are mfa clocks!

Also piped in the carbs with some new 8mm Goodyear fuel hose- im using a Yamaha R1 fuel pump which is easier than faffing about with a FilterKing  :wink:

Nice bit of fabrication work there - when you get 5, how about some dimensions on your gearbox mount.  8)

cheers

Def looks like you are doing well with it anyways, its im trying to fit an 02a box in my mk1, and been trying to figure out when my shafts are in a
straight line, just dont wana spend that money for mounts as you say. Some size's would be  8) . But keep up the good work here and keep us all
updated. 16vmk1 will go really well  

ive but gsxr 600 carbs on mine a drilled them out to 1.5mm to start with the car still dont want to start thow lol and i got the manifold made up for 50 pounds
here is a pic

p.s sorry for the high jacking lol

nice work matey- no need for apologies!!

Is that a Mocal oil cooler i spy… :wink:

Bike carbs need a fair bit of choke to fire up, you got the fuel pressure set ok?

it is mate a 13 row oil cooler on the end of it , and my fuel is comeing in about 1.5 bar on a in line reg from a gold top fuel pump but i could only get the car stared when it was on the webers and that was with a big power pack or toeing it

Hey good to see you got your missus doing a bit,mine's dead keen to help too but by the time i have explained to her what she needs to do i could have done it myself! Still she's good for brewing up!
 Anyway how does the master cylinder and servo marry up to the brake pedal? been thinking about doing this with mine when i pull the motor for a G60 conversion which starts tomorrow,is it the 16v 22. master cylinder you are using?

sis any one see the white mark 1 with a 2.0 16valve running r1 throttle bodies in pvw in januarys issue it looked amazing and thought it was a lovely example of a clean and rust free mark 1

I was hoping for the first startup today but ran out of time (and no help from the sodding weather either)

Finished off the small fabrication jobs- battery tray, wiper motor mount and header tank bracket. These were all missing from the car when i got it, it looked like someone was in the process of smoothing the bay, quite where these bits were supposed to live is anyones guess!!

As usual i made the parts from the olde stock of random plate and tube in the corner of the shed:



Black lines are seam sealer before hammerite topcoat…

The pipe next to the dizzy is the oil breather- at the moment its made from a couple of mk2 pipes, im probably gonna make a catch tank but to get it running i just need some height.

Will take some pics of the footwell to show the pedal alignment etc  :wink:

when are you gone ahve it runing mate , once its done you can come and do mine lol  

mk1ash

hi mate have you got her running yet
 i am going to be running my 2.0 16v on r1 carbs
 and have been told these carbs need 3bar of fuel pressure to run
 hope this is of some help
 good luck

Thats some nice work done to make up the manifolds  :y:  No problems with dizzy clearance on you conversion!!

no aint started it yet mate as ive not put the carbs back on ? soon it will be done lol

vdubbert said

mk1ash

hi mate have you got her running yet
 i am going to be running my 2.0 16v on r1 carbs
 and have been told these carbs nee d 3bar of fuel pressure to run
 hope this is of some help
 good luck

dont you mean 3psi, 3 bar is 40 odd psi miles to much.
your better off running the r1 fuel pump as i designed for the carbs and also works on a points system so auto shuts when carbs dont need fuel.

Posted: Sat Jan 10, 2009 3:58 pm    Post subject: mark 1 with a 2.0 16v on r1 throttle bodies

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  sis any one see the white mark 1 with a 2.0 16valve running r1 throttle bodies in pvw in januarys issue it looked amazing and thought it was a lovely example of a clean and rust free mark 1
 
 

thats mine  there carbs btw  thanks mate