Mellow Yellow 3.2ltr 24v Conversion

You've got a lot of patience Rich  

Tedious innit, welding up all them holes  

That stiffener bar looks interesting  

Had a bout of the old man flu that knocked me for six so haven't had much progress the last 2 weeks but managed to get some time in today Welded the holes I don't need in the front panel, top and front edge and also the tops of the turrets


Seam welded the gearbox mount for extra rigidity and tidied it up a bit on the engine mount side.

I have some wheels I really want to fit but the offset isn't particularly forgiving with G60 calipers.

I dug out my old Gti 256mm calipers with the special carriers that fit the mk1 hubs. Going to trial fit them to see whether they are a better fit with the wheels. Also nice to have a direct fit caliper than using an adapter.

 

Great build mate , brave fella, was this car in golf mag? Previous owner a woman? Looks familiar well she had g60 in her yellow golf. Have g60 in my wagen love the sound although my cuz has vr6 in his mk2 equally nice sound ,funny he has v5 box in his golf and it's got better ratio than vr6 box so he reckons. Best of luck with the build, what are the brake carriers of by the way?


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gafo said

Great build mate , brave fella, was this car in golf mag? Previous owner a woman? Looks familiar well she had g60 in her yellow golf. Have g60 in my wagen love the sound although my cuz has vr6 in his mk2 equally nice sound ,funny he has v5 box in his golf and it's got better ratio than vr6 box so he reckons. Best of luck with the build, what are the brake carriers of by the way?


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Nah not been in Golf mag and no the previous owner wasn't a woman. I put a G60 conversion in her, lasted for a year before I changed my mind and went R32 lol

http://vwgolfmk1.org.uk/forum/index.php?page=topicview&id=projects%2Fyour-mk1-golfs_2%2Fthe-yellow-peril-G60

The brake carriers are from an early Scirocco I believe 

Had a read of your g60 build thread / money pit , I remember it well. Did u ever   get it rolling roaded? Didn't see any figures, there some machine in g60 mode, also when r.j did the wiring loom are all the connectors included or is it just wiring ?


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gafo said

Had a read of your g60 build thread / money pit , I remember it well. Did u ever   get it rolling roaded? Didn't see any figures, there some machine in g60 mode, also when r.j did the wiring loom are all the connectors included or is it just wiring ?


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Never got it rolling roaded, but hey it's not always about the figures, just how the car drives and it sure did that.

I got new connectors where possible and used the existing g60 ones where they were no longer available.

Yep there a beast of a car with g60 engine and you can throw it into bends , corners and with confidence it'll go where you aim it, mine is polybushed all round and like a go kart , be interested to see what you will make of the new engine


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Got the accelerator pedal bracket fabricated Used 3mm stainless steel plate for the brackets and all stainless fittings.


Welded in a bracket to mount the dual remote servo.



Now I can finish off the last bit of grinding and then the sand down begins

Great work, really looking forward to watching this progress. Like you say there ain't much info or guidance out there on this conversion yet.

That engine bay will look slick when finished  

Keep up the good work, it's threads like this that keep us all motivated!

Stevieboy1107 said

Great work, really looking forward to watching this progress. Like you say there ain't much info or guidance out there on this conversion yet.

That engine bay will look slick when finished  

Keep up the good work, it's threads like this that keep us all motivated!

Cheers Stevie

starting to pick up momentum now, only managing to work on the car at the weekends but have some days booked off to speed up progress  

I want to improve the stock sound proofing so the interior is more bearable as the G60 was pretty loud and I'm not too sure about how loud the R32 will be . Also there was a lot of heat radiated from the engine through the bulkhead and without the stock heating system I'm not sure how good the air flow will be So I undertook the thankless task of removing the stock bitumen sound proofing which also gave me the opportunity to inspect the floor for any tin worm.

Before:


Some heat gun and scrapping action:


Started removing the residue:

Finally got there
Thankfully no signs of rust and original floor:


Next going to sand it all down and get some epoxy primer on 

Started today by removing everything from the engine to do the timing chain and replaced everything with new VW goodies
Chain and guides removed


Old bits


new bits on
Also started to remove the 5th gear from my CTN diesel box to go in the CDM Corrado box.


Tomorrow I will finish off the gearbox and start fitting the service parts to the engine  

Great work. Your floor looks in great condition  

Matt

Managed to crack on Serviced the engine, new iridium spark plugs, water pump and oil filter. Added my mocal thermostatic plate.

Modified the alternator bracket so the air con section is removed for more clearance. Added a new diesel alternator with W terminal and mounted up the tensioner so i could trial fit the V belt. Success .

Gearbox is now finished, managed to take the gears off without damaging the teeth.

Next I'm going to remove everything and paint the block and gearbox. Hoping for a trial fit week Friday.

The interior and exterior are on pause at the mo, need to check the radiator, fan assembly and oil cooler fit and the necessary brackets fabbed up before i touch the prep and paint.

pazwaa said

Great work. Your floor looks in great condition  

Matt

Cheers Matt

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It's getting ever closer!!  

Pics of the diesel 5th gear installed, trying to assemble the selector was interesting with the c clips. Think i might be a bit cautious when i first give the box a dry run