G60 16V Tin Top GTi

Oh wow, looks fantastic Greig! Love that cam cover    

Looks great. I particularly like the cam cover.

Have you trial fitted your serpentine belt yet? When I was messing about with mine I read concerns elsewhere about getting enough purchase on the water pump pulley if the belt just runs over it, and others talking about wrapping the belt over the top of it and spinning the pump in reverse (or finding a pump that spins the other way). I can't remember where the dsicussion led to though!

I remember suggesting that on the dubforce forum. Think the conclusion was no as the impeller is designed to spin one way.

Tidiest solution I've seen is to run a tdi needle roller between the water pump pulley and the alternator to give the belt more purchase. Think I'm going to use a toothed belt setup to bypass the whole issue

Laughingboy said

I remember suggesting that on the dubforce forum. Think the conclusion was no as the impeller is designed to spin one way.

Tidiest solution I've seen is to run a tdi needle roller between the water pump pulley and the alternator to give the belt more purchase. Think I'm going to use a toothed belt setup to bypass the whole issue

That's the post I was talking about  

Mine is a hybrid mixture of Bartek brackets mounting the alternator at the back with a bespoke solid tensioner with ribbed 5v belt

I think the alternator tucked down below at the front looks much better but it wouldn't fit with my intercooler setup

Yeah, from my rough mock up there just didn't seem to be any other option then to use a twin pass.

Got to say, never been a fan of wrinkly paint but that rocker cover has made me a convert! Looks cracking.

Back with more of an update got loads to get through! So here we go.. Took my Gti over to JMR to get the old 8V out. Which was done within an hour!



bye bye 8 valve..

Heres some pics of the 16v in all her glory!

i haven't got any shots of the engine going in.. The excitment of it all was to much for me!

But she's in and sitting pretty!





Now the first problem that we hit was the stainless steel manifold was hitting on the steering knuckle. so much so you couldn't even turn left to right without hitting it… So out came the grinder!

The double joiner part  (its the one on the right in the picture below) We cut out a section and turned 180 so it was flat, then added a piece of pipe and welded it in! Sounds easy but it wasnt.. But its donr the job!



















All sorted and lots of clearance



 

I saw this when I dropped my charger off at JMR last week for a re-build, really is a nice car and the engine is unbelievably tidy

Gearbox and driveshafts are all bolted on the next step was fitting the new 2.5 inc exhaust…








Looks the business!

next problem was notching out the front chassis to take the alternator.. Easy for JMR…

fitting the bespoke oil catch tanks and fabrication








Had these two alloy tanks made and joined by a breather system at the top mounted to the same shape as my battery tray.. VHT painted and looks the part..



Hit a problem the the breather pipe along the top was to high so a quick trim and repainted…she's in..

fabricating the intercooler, RS outlet and pipework

Needed to change the intercooler outlet pipes to fit..

bought some 63mm alloy pipe and made it work..











Next on JMRs advice a Volvo oil cooler was purchased and modified to fit





next polo alloy radiator painted and slim line fan added





Now the fun part! making the supercharger outlet work!

bought an RS outlet pipe

















lets hope its works!!

Battery has been moved to the boot Varley red top was needed..



nicely hidden in back side area..

Wilwood calipers and 285mm disc going on at the front







Good old flee bay

Getting it all in…. its tight in there





Love the craftsmanship JMR has done on the injector rail. such a neat job!













So there you are… if only it was that easy! I can't thank JMR enough.. they've been superb throughout
Now to put 2000 miles on and then get it tuned to its full power..

Cheers MPF85 can't thank John enough for way he's carried out the build..

Pure class, take my hat of to you sir

Thanks Harry it's been a real mission.. But to see it in the bay! 

All that hard work has payed of mate, deffo one of the nices mk1's I've seen

Thanks again.. Hopefully I'll bump into you at some shows.
 

Looks fantastic mate!! Love it