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8v tuning project - 158 HP (On for paint!)

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2,0 AGG conversion, G60 PG

New parts and the current pile of parts. The parts for head and engine is by my tuner.

TSR adapter kit with breather block-off, dizzy adapter etc.

Sachs 210mm clutch with 16v pressureplate, GTI 210mm flywheel. Aluminium airhorns, soft mounts, filters etc. image.jpeg image.jpeg image.jpeg image.jpeg image.jpeg image.jpeg

1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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Great build, where did you get the schrick bits from?

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shepp said

Great build, where did you get the schrick bits from?



Thanks :)

Got the camshaft and all the upgrades at: www.bar-tek-tuning.de

They have just about all in that direction for the G60 and 8v platform.

1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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I'm liking this as people have said going the 8v route is different and I like were its going!

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Panch_mk1golf said

I'm liking this as people have said going the 8v route is different and I like were its going!

Thank you - will be an interesting engine when finished :$
Absolutely love your G60 build - keep the posts coming!



1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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Finally got some images from my tuner.

He is actually almost done on the head. It has been completely refurbished with new valve stems and got the royal treatment. Just waiting for the final touches and the cfm-figures from the flow-bench  :P

The engine is also stripped and as it is, the head and the bottom will mate up with my Cometic steel-gasket and give a compression ration of 10,54, which is not enough.

We have decided to skim 1,8 mm off the bottom and to skim the pistonheads to hit a compression ratio of 11,5 - hopefully this should give a decent output  ;)

Need to buy some seals and gaskets and a cambelt kit, for my tuner to finish his work.
seems like there are one million parts I still need to buy :(

Essential next steps is to get the 45mm Weber DCOE's, throttle linkage, fuelpressure regulator and a fuelpump (probably Facet Red Top or a Redline).
Fuel pump will be installed with separate relay, wiring and fuse.

Also got some paint, primer etc for the cleaning and paint of the enginebay.

1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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Hurtig said

Regarding brakes I am going for a 280mm G60 conversion (front brakes).

Got these adapters from eBay yesterday and need to source calipers, carriers, discs, pads and a new brake servo/booster from a 16V.







If you are still looking for a MK2 16v Brake servo I have one for sale.

Last edit: by Pincher

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Interesting build.
@kamikaziecabby you'll be interested in this too

Cornish Host.
1980 VW Derby
Clive the Cabby
Ujum the Invisible
Mynx the  Tintop

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Liking this build I'm rather interested to see final power output. Should have a decent sound track, so far so good I'd say 👍.

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Pincher said

Hurtig said

Regarding brakes I am going for a 280mm G60 conversion (front brakes).

Got these adapters from eBay yesterday and need to source calipers, carriers, discs, pads and a new brake servo/booster from a 16V.

If you are still looking for a MK2 16v Brake servo I have one for sale.

Hi Pincher,

What is your asking price? :)
Pincher

1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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vdubdan7 said

Liking this build I'm rather interested to see final power output. Should have a decent sound track, so far so good I'd say 👍.
Thanks vdubdan7,

I am also really interested in seeing the dyno output.
Initially I was going for a 276 cam, but opted for a 288, as the idling is not a problem to sort with twin DCOE's and thereby one barrel for each cylinder.


Must admit, that I'm hoping for quite more than 160 HP. My tuner is more in the region of 170 HP, but time will tell and the feeling on the road is worth more than the digits on the dyno.

Will post a sound video, whenever possible - then you can judge for yourself ;)Also got some goodies for the tackling of the enginebay :wub:Rattlecans with RAL-color matching the paint, clearcloat, primer and some undersealer for the underside. Got a nice kit of hose clamps, that I just had to have, as well as wipers all around.

Hope to be able to get cracking at doing the bay this weekend.


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Last edit: by Hurtig


1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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Tackled the bay this weekend.


Got rid of excess cables and tidied up a bit. Got it all sanded down by using a steel wirebrush and good old sanding paper. 

Finished it off with primer and new paint. On the pictures there are two coats and no clear coat. Next time I will give it the finishing paint and finish with clear coat.

Also gave the brakebooster a lick of fresh black paint. Really pleased with the result.

Also painted the bottom and the sills with stonechip protector - also really pleased with that :)

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1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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Also released the gearbox from the old engine.

Need to clean,  wirebrush and paint it :)

Also got a load of new bits stripped from the old engine, ready for refurbish and to find it's way to the new 2 litre powerplant :)

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1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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Time for an update.

Gearbox now painted.
Really love how good it turned out :) Brake servo got a lick of black gloss spray paint as well.

Also fitted  scuttletray, washerbottle, grille etc

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1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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Also got the engine back from my tuner.

He has assembled it with head, headgasket and timed it in and fitted cambelt. I will assemble the rest myself.

The CR ended up at 11,35, which is spot on what I wanted. I will run it with 99 Octane V-Power to avoid any knocking.

The bottom was skimmed/decked 1,7mm and the piston crowns machined down to fit.

The head flows 165cfm, which equals to about 180 HP in terms of flow - really pleased with that. He advised to open the inlet valves slightly sooner (6-8 degrees), as there is plenty of space and the 288 cam in his opinion is not that wild.


 

My tuner spent 80 hours on the engine with disassembly, balancing, grinding the valves/seats etc.
The bottom was boiled and all holes cleaned with a special (long) wire brush tool. 


 Will run it with Castrol 10W-60.

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1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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Weeeeeee :) Received my carbs!

Got a pair of 45mm Weber DCOE 152G with the new style emulsion tubes, for a smoother transition.
Also got a Facet Silvertop fuelpump and a Filterking fuelpressure regulator with gauge.

Got it all by Andrew at Fastroadcars - good guy!

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1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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Was SO lucky to find this very special 1983 Volkswagen GTI "Campaign" from Sweden.

It has all the equipment of a real "Campaign" and even features headlight washers. It also has the correct sticker in the boot and the correct VIN.


The car was ideal for me as the engine and gearbox was missing.

The car is not perfect, but the sunroof is immaculate with no rust and works perfectly.


Will begin with the car in the winter.

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1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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A lot is going on at the moment - can't wait any longer!
Got the fpr fitted along with the Facet pump and got the engine on the crane.

Not long untill it is ready to go in! 

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1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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Clutch, flywheel and gearbox fitted!


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1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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Not really much feedback from you guys?

I finally reached the "Marriage" :D

The engine is is.

I am hoping to be able to fire it up, already this weekend.

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1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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