Golf mk1 2,0 Gti Berg cup project

does the intake manifold from a audi 80 fit the golf engine head? thought about collecting the audi throttle body and using a dremel to make it fit the intake manifold.. but would be easier if i had a separate manifold cause I'm using the car daily..

but the throttle body to use is the one from audi 5 cyl engine right? then i couldn't use the intake manifold, hehe..

what else is useable from the audi enging? wur?

Picked up the black diamond clutch kit today, looks nice but small


The head ready for 20nm torque, going to change the cam sprocket to the adjustable in the picture


Setrab-oil cooler, cleaned with thinner, going to mask of and put som paint on the frame.


Otherwise, haven't done much, just ordered some spare parts, sensors, topmounts, filters and som other stuff.

Not much done here.. lack of funds.. still need to get the crankshaft balanced, also need a new exhaust manifold for the tall block.. new costs 450$ at techtronics tuning.. anyone know another shop for a cheaper exhaust manifold??

anyways.. had a boring day.. not even sure i'm going to use it.. it's the lower part from a k-jet in volvo, it replaces the air filter box and allows to use an open sportfilter, the conical type..

not finishet, but looks a lot better than before..

A pic of the painted oil cooler, it's a setrab 13 rows. It was a bit shabby but I cleaned it up and removed as much of the old paint as possible. The new paint is heat resistant.. but we'll se about that..

Because of the lack of interest/comments in this thread I stopped updating long time ago.. But much has been done and I thought I at least could show the results.

MrPete said

Because of the lack of interest/comments in this thread I stopped updating long time ago.. But much has been done and I thought I at least could show the results.

yip
nearly 3000 views & only a few replies  :dontknow:
baz

2,0l AGG, ported and skimmed head, 276 degree cam, lightened, balanced, new bolts, bearings and so on.


Ported intake manifold for the bigger audi throttle body


All bushings are new urethane


Meterhead from volvo 240turbo, adjustable fuel pressure, better airflow and capacity.


new topran hoses


Engine bay empty, painted with primer


bodykit in the wheel arches


Home made shift linkage, metal ball joints


Bad quality photo.. but the engine bay is now black


Picked up som glassfibre parts


Trying arches and berg cup kit




Engine in the house!


Polished the intake manifold, just roughtly..


Installed an oil baffle




New wishbones with urethane bushings


The front so far


Mocal oil sandwich with thermostat


New ray simons exhaust, 2"


Installed under the car, with wideband lambda


Needs to be shortened..


Working on the front arches






Installing the battery in the back, just trying the fit


New 35mm2 battery cable


Fat ass






More coming, the car will be finished this summer

Hej That's gonna end up a beast!!!  Good work going on there!

geejah said

Hej That's gonna end up a beast!!!  Good work going on there!

Thanks! I sure hope so Looking for rims at the moment.. 14-15x9" but theese are hard to find… found a guy that rebuilds rims so it's hopefully solved soon. Going to start the engine in a few days now, vid coming up then

Great work man. The arches and fibreglass gear look sweet. Nice build and Mad skills on the mechanicals.

Great work man. The arches and fibreglass gear look sweet. Nice build and Mad skills on the mechanicals.

Gillie said

Great work man. The arches and fibreglass gear look sweet. Nice build and Mad skills on the mechanicals.

Thank you! The glass fibre parts were pretty easy to fit, of course I could work more on them, especially on the rear fit against the torpedo wall. It's nice to hear, done almost everything on my own. My first complete engine build. Hope it runs, hehe

I hope it runs for you too mate.  The engine rebuild is something i'd love to do one day .  I'll work up to by getting through all the other little jobs on my golf first though, as I'll need all the practice i can get.
Good luck

Gillie said

I hope it runs for you too mate.  The engine rebuild is something i'd love to do one day .  I'll work up to by getting through all the other little jobs on my golf first though, as I'll need all the practice i can get.
Good luck

Yeah, me too It's shouldn't be any problems, but you never know for sure. The engine build was pretty easy but expensive. Allthough I was lucky to find a complete bottom end, cleaned and with new bearings and gaskets. Just got everything balanced and lightened incl. the flywheel. Skimmed the head 1mm for 10,5:1 compression ratio. Head ported by ultra motor, 276degree cam, adjustable sprocket. oil baffle in the head and the sump. I also took off 1mm from the intermediate shaft, it's badly balanced as it come. The only thing I regret that I didn't do was to get the supertech valve spring kit, with titanium retainers.

There's also k-jetronic from volvo 240 turbo, wich gives adjustable fuel pressure and better air flow. good for 220hp at least.. well, won't come that far with this setup, but it's better than the golf k-jetronic. Also fitted the b23ft fuelpump (bosch 909) brand new.

There's a lot things done, but there's allways more to do

Spending time and money getting it right will pay dividends as you'll know the job is done correctly first time.  Good tip with the Volvo K-jet system also, I hadn't seen that before.  Looks sweeeet!
Keep up the good work!

Gillie said

Spending time and money getting it right will pay dividends as you'll know the job is done correctly first time.  Good tip with the Volvo K-jet system also, I hadn't seen that before.  Looks sweeeet!
Keep up the good work!

Absolutely. Yeah, got the tip from a guy that have been doing this for many years. It's oldschool but it works. Especially when you use the 2litre engine block, it needs more fuel. You could also just take the pressure regulator from 240 turbo or saab 900/0 turbo and bore the backside to get to the skrew for fuel adjustment. The membrane that gives more fuel when turbo i spinning is just blocket off.

Here's a new pic, last one before I put "shoes" on 14x9" widened steel rims with Toyo Proxes T1-R 225/40R14



Yesterday I also shortened the exhaust tip, just before the chrome part, angeled a little to the left and up, looks sweet I say



And put mine and ze wife's names on the rear window



Also working on some downforce.. the "horns" are cut off, to complicated.. will do some experiments with the wing to try to get a smoother surface.. it's not easy..

Here we go! The car has been at the mot test

They couldn't test the brakes because the car is TOO LOW, hahaha.. otherwise there was nothing to complain about. So I can now drive legally one month, then I have to go back and test the brakes. There's coilovers so there's not a big issue.

Here's the almost finished result

Some new stickers, getting race ready









Funny sticker

Very well done. Is the passat engine a tall block and if so which manifold did you use. Liked the use of the volvo 240 turbo fuel regulator, never seen one of them used before

Cero said

Very well done. Is the passat engine a tall block and if so which manifold did you use. Liked the use of the volvo 240 turbo fuel regulator, never seen one of them used before

Thanks! Yes, it's the passat AGG block (-95) together with a mkII gti head, ported and skimmed 1mm. I used a Ray simons exhaust header (swedish made) It's built for 1,8 engine, but there is clearance. Otherwise there are special made headers made for tall block at techtronics, but they're expensive.

I think you can use any exhaust header from ebay, sometimes people get interference with steering column or gear linkage, but there was no problem in my case.

The Volvo turbo fuel regulator is a good investment, especially with the metering head and all. Good for more power than the golf stuff. Another good thing is that you cant see any difference if you don't know what to look for. (thinking of MOT-test)