Author Topic: Projekt Golf Zwei  (Read 23141 times)

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Offline 80 Vert

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Projekt Golf Zwei
« on: June 28, 2020, 12:08:36 pm »
New project.....
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

Offline brian

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Re: Projekt Golf Zwei
« Reply #1 on: June 28, 2020, 12:15:26 pm »
Waiting
V̶W̶ ̶P̶o̶l̶o̶ ̶1̶.̶6̶  Škoda Fabia 1.0 TSI Race Blue

Offline 80 Vert

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Re: Projekt Golf Zwei
« Reply #2 on: June 28, 2020, 03:50:35 pm »
As many will know I used to own an 89 16v many many years ago and I've never really forgotten that car. Over the years I've been pretty fortunate to build some pretty rad mk2's for people but recently I did my most favorite one for Rambo005.
His oem plus 12v VR6 swap set something in motion urging me to start looking for another mk2.
I'd always kept half an eye on the market and while surfing TM one Friday night I stumbled on a 91 big bumper, sunroof 3 door. My ultimate mk2.
It was too much money but called the guy and went to see it the next day.
It was clear very quickly it needed a LOT of love but the basics were there, bonus mk3 Recaros already in place and mostly straight, rust free, already had 5 stud hubs etc. Few small rust spots but nothing I can't handle.
Very poorly executed ABF swap which I knew immediately would be going anyway and replaced with a 2.0TSI from a mk6.
I wanted something no one had really done before and something technically challenging.
Seemed to drive ok and felt kinda neat to be back behind the wheel of a classic Golf.
Deal done and took it home.
The harder I looked the more I found, many bodged repairs and barely anything worked so the first thing was to repair the 1" plus travel in the gear mechanism before it did anything. Machined new bushes to remove the slop and sort that for now until I updated the entire shifter box.
Sunroof didn't work, took that apart to find missing components and seized mechanism. I made the parts that were missing and broken. Once adjusted properly to again have a working sunroof.
« Last Edit: June 28, 2020, 04:25:15 pm by 80 Vert »
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

Offline 80 Vert

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Re: Projekt Golf Zwei
« Reply #3 on: June 28, 2020, 04:33:40 pm »
As is often the case these things are slammed to the ground on cheap rock hard coil overs, this one was no different. Yip they had to go, and go immediately.
Took them out and fitted some temporary oil shocks with a new set of Eibach lowered springs, fitted some 8L S3 312mm front brakes at the same time which *just* fitted inside the 16" Work Pietra Corse wheels I intended to keep even though all 4 were kerbed 360 degrees and the center caps were all broken.
It seemed reliable enough so I kept it on the road while slowly working on the interior.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

Offline the phantom

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Re: Projekt Golf Zwei
« Reply #4 on: June 28, 2020, 10:00:58 pm »
looks promising, very promising
Land Transport New Zealand, taking the fun out of driving since August 2008

Offline Poonmobile

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Re: Projekt Golf Zwei
« Reply #5 on: June 28, 2020, 10:50:13 pm »
Its complete!!!
Current:
06 NZ B7 RS4 Avus Silver, 01 NZ B5 RS4 Avus Silver, 93 NZ VR6 Tornado Red 3dr, Renault Clio 172 & Renault Clio 197
Past:
MK2 VR6, MK5 GTI, 2 x MK5 R32, 8L S3 Imola, MK4 Golf V6 4MO, Polo GTI, 2x MK3 VR6, D2 S8, B5 S4 Avant, 03 NZ R32 Deep Blue Pearl, Renault Megane R26 liquid yello

Offline mark2 golf

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Re: Projekt Golf Zwei
« Reply #6 on: June 29, 2020, 07:44:51 am »
Nice. Good to see another real project.
89 mk2 1.8t
97 mk3 gti 1.8t
02 Allroad tdi
99 s430 merc
90 190e 2.6

Offline Johnnytron

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Re: Projekt Golf Zwei
« Reply #7 on: June 29, 2020, 08:04:36 am »
Soo cool to see this is still on the road.
I owned it from 2005-2011. Owned it as a student and could only really afford to keep it running, but eventually I had the original 8v 1.8 rebuilt and it was an absolute gem. Did several track days at Ruapuna. I eventually sold for a 2002 S3 as I felt it was time for a change.. I had instant regret.

Bit sad to see it's not as original, but awesome that it's still alive and being enjoyed!! Well done.

'14 Skoda Octavia RS Wagon
'12 VW Cross Polo
'12 Renault Sport Megane RS250 - Sold
'02 Honda Civic Type-R - Sold
'02 Audi S3 - Sold
'91 VW Golf Mk2 GTi 8v - Sold

Offline Johnnytron

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Re: Projekt Golf Zwei
« Reply #8 on: June 29, 2020, 08:08:23 am »
This was owned by Brian before I owned it.
'14 Skoda Octavia RS Wagon
'12 VW Cross Polo
'12 Renault Sport Megane RS250 - Sold
'02 Honda Civic Type-R - Sold
'02 Audi S3 - Sold
'91 VW Golf Mk2 GTi 8v - Sold

Offline 80 Vert

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Re: Projekt Golf Zwei
« Reply #9 on: June 29, 2020, 09:05:59 am »
Interesting, looks great in that picture. I've only owned it 18 months so it's really gone down hill in the last 5 years.
Clear coat is peeling off in places etc.
Never mind tho, in good hands now.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

Offline Johnnytron

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Re: Projekt Golf Zwei
« Reply #10 on: June 29, 2020, 11:32:25 am »
yeah great to see it's in the hands of someone that loves it. Special little car
'14 Skoda Octavia RS Wagon
'12 VW Cross Polo
'12 Renault Sport Megane RS250 - Sold
'02 Honda Civic Type-R - Sold
'02 Audi S3 - Sold
'91 VW Golf Mk2 GTi 8v - Sold

Offline 80 Vert

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Re: Projekt Golf Zwei
« Reply #11 on: June 30, 2020, 09:29:49 pm »
With the car on the road and useable I started planning the swap. I had a rebuilt EA888 engine and another broken one which had suffered the failed tensioner so that seemed like the logical choice.
Stripped the engine down and found 16 bent valves, 2 broken roller rockers but thankfully no holed pistons or cam damage.
Valve impact marks on the pistons but nothing major. Chucked the stripped head in the degreaser tank to soak the carbon off and ordered 16 new valves, new roller rockers, head gasket, head bolts and a new timing set.
While I waited for the engine parts I started thinking about what gearbox to use, I wanted to stick with the smaller lighter 02A 5 speed (the car had one in it already) with gear ratios matched to mk2/3 wheel / tyre size.
I ended up buying a spare one off Anton to pull apart and rebuild. At that time no one made a flyweel for that swap so I made my own.
ABF / 1.8T are 6 bolt, TSI are 8 bolt. Can't use TSI flywheel as these are 240mm for 6 speed.
Got the South bend clutch and flywheel out of our old Vento track car and decided to modify that.
« Last Edit: June 30, 2020, 09:33:15 pm by 80 Vert »
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

Offline superfueler

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Re: Projekt Golf Zwei
« Reply #12 on: July 01, 2020, 04:36:30 pm »
A beautiful golf you have there 80 vert, a real gem.
Current: 2010 Audi A4 2.7 TDI silver, 2017 Ford Ranger 3.2 Px2 DC frozen white.
Past: 2004 Golf R32 black pearlescent, 2009 Audi S3 white, 2004 Audi A4 B6 1.8T blue, 99 Golf mk4 GTI black, 2005 Audi A4 B7 2.0T black.

Offline 80 Vert

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Re: Projekt Golf Zwei
« Reply #13 on: July 05, 2020, 09:17:23 am »
Using the ABF flywheel wasn't going to work as its cast steel, not a good idea to weld.
The old Southbend flywheel and clutch from the Vento track car however was billet steel, this will work.
First I made a solid drill jig from a thick lump of steel, using the dsg flywheel as a guide for the hole spacing.

Flywheel next, chamfered the holes and welded them up, let it cool slowly and back in the lathe to clean up both faces.
Once machined my drill jig locates firmly in the new flywheel to drill the 8 new holes.
One unfortunate thing I didn't count on was how hard weld material is to drill through. Near impossible with ordinary drill bits!!

I must have sharpened that drill bit 20-30 times to get those suckers drilled. Got there in the end but took ages.
Sent the clutch assy out to be balanced and whammo the first problem solved.

2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

Offline 80 Vert

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Re: Projekt Golf Zwei
« Reply #14 on: July 05, 2020, 09:25:26 am »
With a box of new parts arrived I fished the head out of the degreaser and finished cleaning it, all new valves and roller rockers went in. Car was staying true to the badge it was wearing on the grille. 16V.........all be it enhanced just a little  :laugh:
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

Offline 80 Vert

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Re: Projekt Golf Zwei
« Reply #15 on: July 12, 2020, 10:06:58 am »
Searched through my boxes of crap to find a turbo with only 10k km on it which would be ideal for this build. Managed to piece 99% of the engine together out of stuff laying around. Bought a new inlet manifold as these pox out on a regular basis and didn't want the hassle of pulling it all back apart later on.
Had a complete engine wire harness as well but no ECU yet or car side harness, really needed access to a whole wreck for that part.


With most of the engine together I really put some thought in to how all of this was going to work, it had to have AC and a mk5 set up just wasn't going to work due to the variable vane compressor. I would find out later just how difficult this was going get to enable it all to work!!
Decided to go with a mk4 pump, MK3 AC box and custom everything else made up of Mk 2,3,4 and 6 parts.
Made a mounting bracket to attach the Mk4 pump to the Mk6 engine, a Mk3 belt was just long enough to do the job.

Put the engine aside for a while and started looking at the interior, oh boy!!
Someone thought they would "fix" the headliner, as I'm pulling it out it was becoming clear that things had not gone well.
It had been glued together poorly with fiberglass and looked like utter crap, really needed a new one but try and find a good used sunroof headliner.
Once stripped of fiberglass and covering I was left with a board broken in 4 pieces. No choice but to figure something out.
The base board is made from styrene which over the years becomes brittle and starts to crumble. Started making repairs with epoxy glue at first filling holes and getting a basic shape.
Glued the main sections back together and used foam, filler and epoxy to keep working the shape and lines / contours etc.
Sounds easy enough but it really wasn't, this headliner has over 35hrs in it to turn it in to something useable.


« Last Edit: July 12, 2020, 10:19:07 am by 80 Vert »
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

Offline 80 Vert

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Re: Projekt Golf Zwei
« Reply #16 on: July 15, 2020, 07:45:58 pm »
I forgot I had this pic, shows just how fu#@ed the headliner board was, still find it hard to believe I managed to save it.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

Offline NasTnaS

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Re: Projekt Golf Zwei
« Reply #17 on: July 16, 2020, 06:46:58 am »
Have I got a job for you... haha
...Nigel Aston
1971 Porsche 911T
1989 Volkswagen Golf GTI 16V
1989 Peugeot 205 GTI 1.9
2009 Renault Megane R26

Offline LouieP

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Re: Projekt Golf Zwei
« Reply #18 on: July 16, 2020, 07:20:24 pm »
Unsure if you mentioned this but did you use an o2a or o2j box?
2014 MK7 Golf GTI - Pure White
1996 MK3 Golf VR6 - Black Magic Pearl

Offline rambo_005

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Re: Projekt Golf Zwei
« Reply #19 on: July 16, 2020, 07:41:18 pm »
...I wanted to stick with the smaller lighter 02A 5 speed (the car had one in it already) with gear ratios matched to mk2/3 wheel / tyre size...