Mellow Yellow 3.2ltr 24v Conversion

Oh boy, this is going to be good, can't wait to see the finished product and will be keeping my eyes peeled.  

the main problem with the tensioners and brackets when i looked at this, all kept the PAS pump, so for fitting, the mk4 R32 brackets and pullies are used.

Also the MK4 fuel rail is used, the MK5 BUB engine doesnt have a return line, is constant pressure (not sure on the right term, but there is something else wrong with the MK5 rail that i cannot remember), so you will also need the MK4 fuel rail and FPR.

The thermostat housing items and oil cooler are binned for the MK3 VR6 items, the BUB oil cooler is too big and will contact the front of the car. Not sure what eurowise has done with there new R32 mounts, if this is something that has been looked at and they have moved the engine backwards in the bay, then you can keep the BUB oil cooler?

You will need the DBW pedal from a MK5 golf, they are all the same, so don't worry about finding a R32 specific one, unless you want the aluminium pedal; this does mean that you will need some of the interior harness.

Wiring as always is the hold back on these, my mate dropped a BUB into a MK2, ended up with MK3 clocks, so like you mentioned rubjohny would be the best answer on the wiring.

Any reason for the V5 gearbox? The MK3 VR6 gearbox flywheel and clutch all bolt up to the BUB, unless the V6 does the same?

Looked at doing what you are doing, but decided on the MK3 VR6 approach instead, just more documented and i know i can do it

All the best though! the 6-Cylinders in a MK1 are just made to be there!

bucket said

the main problem with the tensioners and brackets when i looked at this, all kept the PAS pump, so for fitting, the mk4 R32 brackets and pullies are used.

Also the MK4 fuel rail is used, the MK5 BUB engine doesnt have a return line, is constant pressure (not sure on the right term, but there is something else wrong with the MK5 rail that i cannot remember), so you will also need the MK4 fuel rail and FPR.

The thermostat housing items and oil cooler are binned for the MK3 VR6 items, the BUB oil cooler is too big and will contact the front of the car. Not sure what eurowise has done with there new R32 mounts, if this is something that has been looked at and they have moved the engine backwards in the bay, then you can keep the BUB oil cooler?

You will need the DBW pedal from a MK5 golf, they are all the same, so don't worry about finding a R32 specific one, unless you want the aluminium pedal; this does mean that you will need some of the interior harness.

Wiring as always is the hold back on these, my mate dropped a BUB into a MK2, ended up with MK3 clocks, so like you mentioned rubjohny would be the best answer on the wiring.

Any reason for the V5 gearbox? The MK3 VR6 gearbox flywheel and clutch all bolt up to the BUB, unless the V6 does the same?

Looked at doing what you are doing, but decided on the MK3 VR6 approach instead, just more documented and i know i can do it

All the best though! the 6-Cylinders in a MK1 are just made to be there!

Hi chap,

Thanks for all the info. Re the fuel rail, you can use the mk5 one. You need the fuel filter for the engine which has an integrated fuel pressure regulator and you get the return from there.

I will remove the stock water heat exchange unit and have a mocal kit ready to go on . The eurowise kit for the r32 is meant to allow the stock cooler to be kept. The design changed from the 12v mount kit.

The reason I went for the v5 is it has better gear ratios and is newer than the AAA vr6 boxes. The vr6 flywheel and clutch will work with the v5 as well

Should be able to use standard clocks and have a plan already

Cheers

Rich

well that is all good news then!

How much better is the V5 on ratios? And in what way, shorter ratio for drive ability or something else?

bucket said

well that is all good news then!

How much better is the V5 on ratios? And in what way, shorter ratio for drive ability or something else?

Yes the V5 has shorter gear ratios but will need to change out 5th gear as it will be too short for the motorway.

Managed to find a bit of free time in between building my extension and saw my gear box looking sad in the corner. It was in a real state before I started!

Bit of degreaser and the power washer and got it looking better. I then brass wheel brushed the aluminium oxide off.

Not sure what finish I should do it in yet.


Also got a new rocker cover powder coated black hammer finish with silver vein.



 

Had a bit of a break since my last update but ready to get on with the build now.

First sorted out the garage so I wasn't falling over myself:


The engine has some room now so I can get around it better.


Took the wings off for better access and not to damage them during the conversion.


Took the brake bar off as I have a dual circuit remote brake servo setup to go in
Took the heater set-up out as plan to use an E36 electric heater I have.


Quite a sizeable chunk of space now the heater system is out.

 

The plan is not for everyone and I appreciate there may be some purists that say its sacrilege to do this but the car is mine   its not a gti and will never be as desirable as a stock gti, if I had a Gti I would keep it stock for the record The engine is large and I had some fun with the last G60 conversion with lack of space. I'm going to remove the rain tray (in a humane way so it could go back on )…. weld the fan hole shut as to not asphyxiate anyone in the cabin.

No over the top shaving, chassis legs will stay the same, a few redundant holes in the bulk head removed with tabs.

Battery tray removed and battery / washer bottle in the boot. Remote brake servo under the dash where the heater was along with the electric heater.

I'm going to prep and paint the complete front end, bay, inner wings and front and then the fun starts with the new engine  

I'm looking forward to seeing this go in - should be a bit of an animal!  

Gets the thumbs up from me Rich.Like where your going with it .Did you manage to get in contact with Matey from Newton abbott regarding the install of his R32 lump ?.

Hairyarse said

I'm looking forward to seeing this go in - should be a bit of an animal!  

Cheers chap, I hope so but quite a few hurdles and the wiring makes me cry inside    

FXTURE said

Gets the thumbs up from me Rich.Like where your going with it .Did you manage to get in contact with Matey from Newton abbott regarding the install of his R32 lump ?.

Thanks bud. Nah no one really wants to help with the specifics. I have a good idea of what I need to do and will share the secrets

 Got the dash & steering column removed today
Yes the car was originally blue And now the contentious bit 

Great work thus far.. keep the updates coming  

Gotta say Envy alert.. id be far ahead with mine if  i had the Garage /workshop you've got there Rich.I think i spot a heater too

Nice one

Loving this

Nice tidy up in the garage, got to keep some order

Following this with interest!

I keep seeing vids on Instagram of that red R32'd mk1, sounds brillaint   

Good work so far. Shall be keeping an eye on how this goes  

did you get the rain tray out in one piece?

i was impatient and cut it out in 3…

but after a few years realising if i ever got stopped by the coppers they would probably take the car off me i just bought a complete front end and I'm going to weld my vin onto it and then re install the rain tray      

i may even re open the heater box hole

dont get me wrong it looks great but its slightly worrying as the car needs to be identifiable by a number that forms part of the chassis in the original location

G60RGE said

did you get the rain tray out in one piece?

i was impatient and cut it out in 3…

but after a few years realising if i ever got stopped by the coppers they would probably take the car off me i just bought a complete front end and I'm going to weld my vin onto it and then re install the rain tray    i may even re open the heater box hole dont get me wrong it looks great but its slightly worrying as the car needs to be identifiable by a number that forms part of the chassis in the original location

Hi George,

Yep got the raintray out in one piece, have photographic evidence and can be welded back no worries I was thinking of welding the VIN at the back of the heater fan hole to protect it from the elements but worried it may get covered by paint  or even arrange for the strut towers to be stamped officially.

I will have the riveted plate in stock location.

I always planned to keep my Golf for the long term and as I said it's only a 1.1 shell. I'm handy with a welder and spray gun so nothing is impossible to return to stock.

Yesterday managed to get an hour in mainly to get the car ready for the big weld on Monday.

Safety first pulled the fuel lines out the way and capped them off. Going to run stainless lines eventually.


I removed the front carpet and seats to avoid any welding splatter trashing them.

Re protecting the car when welding I have quite a large welding blanket  which I used for the inside but needed something else for the windscreen.

Tip of the day - I bought a pack of 3 x 1m2 fire blankets of ebay for a tenner which are the same fibreglass treated material as the welding blanket. They worked a treat covering the top of the car.

I cleaned up the loose material left after drilling the spot welds and rain tray and welded a few unavoidable holes where the metal was stressed when removing the brackets.