mk1 20vt and mk1 PD

here is my project i have had it a fair few years it was nearly finished a few years back but get set back by other projects and stuff  

since i got a part time job over at crazyquiffs its given me the insperation to get on and finish the damn thing  8)

here it is when i got it

here is a few random shots of the mk1 over the years

then I had a year or so off of it when i built my mk1 G60 daily, when that was sold i got back on it and then it looked like this

 

then i lost inspiration again and now another year has gone by (and a few more project cars) and ive decided to remove the carb engine i had and fit a nice modern engine

the old engine





the new engine



needed a bit of a clean up

here is bits ive been doing to fit it in and parts i have gathered

brand new 100mm driveshafts with new inner and outer cv's



a new fuel pump, hose and stainless steel bracket





next the timing cover needed modding as the mk4 mount hole isnt needed any more



so i cut a plate out to fill the hole



got the mount fitted and cambelt tentioned  



got one of crazyquiff stainless fuel pump brackets, as nicely made as they are they aint shiny enough lol

before



1st stage of polishing



i welded the cambelt cover up

100mm primed and in base coat, also i noticed these are same size shafts rather than the larger girth long one meaning i wont need to do the chassis notch now as it sits on the chassis leg when the air is on full drop at the moment this should give me the clearance



and a few more shiny bits

oil return for the turbo



head shield for the turbo too



a few silicon hoses for the heater matrix bypass



o2A mount



ditched the shitty duel mass mk4 clutch for a abf flywheel, just need a VR6 clutch join it





fuel rail on





constant velocity joints painted



did a bit more rerouting this time the water cooler for the turbo charger

in this 1st pic u can see the pipe originally come round the cambelt side to the solid front water pipe that goes around the engine



so with a bit of cutting and joining im left with this



still goes on to the solid water line just a bit further on, all hidden on the back of the engine now  8-)

i ran it down low to keep away from the exhaust manifold but ill prob still cover this in heat guard too  

gave the driveshafts and starter a coat of 2k clear



then knocked up a EGR valve blank and polished it finished off with stainless button head M6 bolts



then another short pipe blank for the turbo reroute i did yesterday



and spent the rest of the afternoon making the gearbox mount look pretty

before



bent a few bits of sheet steel in the folder and welded them in place





and then smoothed off





and trail fitted

one removed engine



got a bit wet  :roll:

and back in it home



top hose



oil cooler pipes from a agu 1.8t (more suited for my simplified engine)



new short run aux belt (now only runs the alternator)



a set of polly mk1 axel bushes that i will be using to make my new front and rear engine mount



got the driveshafts completed today





and finished putting the starter back together



re-manufacturing the front snubber mount

there was nothing wrong with vw's original design i just thought i could do better  

start off with i made some new mounting tabs for the cross member part of the mount



then tacked in place



then a bit of cutting and welding later i had



then i modded the engine side of it and mounted the tube for the bush



and voila

one new engine mount



had a few more bits turn up

i had various new banjo fitting turn up including a special nut for the fuel pump



i cleaned up the fuel pump sponge, it came up a treat considering its 28 years old and been under a car in the grime for that long  

all fitted together



then the new fuel filter, bracket (used a coil bracket) banjo



just need some fuel lines now.

a few more bits from vw

100mm driveshafts washers and a gasket from the turbos oil drain pipe



and last up is a new LUK clutch from a 2.9 VR6 so it should take the extra power nicely


 
treated and etch primered the new mount ready for a top coat

 



then i made a plate to mount the boost pressure sender into the intercooler, u can buy a pipe section from forge to mount this in but i want it tucked away out of sight  

this is where it mounts in the mk4 i/c



so i dug out a bit of 8mm aluminium



then drilled a 17.5mm hole in it with a bit of a taper to help the o ring slide in better

and drew round the sensor to give me a guideline



then tapped 2 M6 threads in and cut it out to shape



then checked the fitment with the sensor, finished off with some s/s bolts and washers, it ready to be tigged onto the intercooler  8-)





a forge 007p divert valve (a must for any uprated 20vt)

Welcome to 20VT club mate.
You have skill, i m sure your car gonna be show winner :wink:

Keep us posted!!!

Haha, have you got OCD or something ?

Good work…..keep it coming !

Very nice work

Once i get bored of my carbed valver, i'll more than likely go down the 20vt route aswell

love the wheels lovee the car its gonna be a animal  :twisted:

Nice work man, looks like you know what your doing, and looks real good quality, cars looking lovely

Quality work mate
Will come & say a hello the next time i am at Quiffs :wink:

Cheers everyone  8)

heres a few pics of the fully rebuilt Ko3s turbo done by my mate at owen developments





i doubt it will stay long as he is in the process of getting the bits together to build me a ko4 in a ko3 housing with a new owen development actuator  

i will be getting my ecu back next week too with the immobliser defet and remap

started on the wiring now

i spent about a hour removing the factory cloth loom tape that was covered in glue and ended up with sticky fingers  :?  

then i started removing all the unnecessary parts of the loom that went to the n112 valve the sai pump and pas switch etc

a few diagrams and notes i had made



the main engine loom



the interior power to engine loom




and the bits removed



now i have my head round it in theory its as easy if not easier than the abf, G60 wiring's i have done before.

very nice, be great to see this one when its finished, lovely car !

This car is just super clean looking, really looking forward to seeing this engine in that bay I really liked your red mk1 G60 conversion you did, keep up the amazing hard work.

Amazing - how much have you spent on it?

thanks for all your comments

i have no idea how much i have spent, i dont dare tot it up  

time to finish off the full race spec brakes that i started a few years back

i already have wilwood 4 pot front brakes mk4 turbo rear brakes with a tilton bias (fully adjustable pressure to the rear brakes)



it was just the master cylinder left, i had a mk2 16v non servo one fitted direct to the pedal before but as I'm repainting the bay i might as well get rid of that too

so now im going for the fully hidden twin cylinder with balance bar and a remote servo to remove the hard pedal feel

the remote servo that i will tuck under the dash if i can find space



the balance bar



the cylinder



ill be mounting them all on the original steering column

i need to cut up the spare column i have now, it will be the most modded pedal box u can get on a mk1 with hydraulic clutch, twin cylinders and electronic throttle

looks sexy mate, did you spray it yourself ?
wonted some tips on how you sot such a mint shiny finish ?
is it all in the high gloss lacquer or polish the f**k outof it ??
should be spraying my mk1 g60 project for the 1st time

hiya mate i didnt paint it as i dont have the facilitys to paint something of this size

it is a base and clear paint job that has also been wet flatted and porter cable polished up to the glass like finish