Author Topic: Projekt Golf Zwei  (Read 12029 times)

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Offline 80 Vert

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Re: Projekt Golf Zwei
« Reply #60 on: November 08, 2020, 05:12:55 pm »
Paint drying worryingly slowly I put the electro hydraulic power steering pump together and modified the bracket a bit more to get it centred in the hole I'd cut. Once the pump was in place I assembled the front sub frame with all new bushes, ball joints, tie rods and wheel bearings. Mainly to get the steering rack installed to enable new feed and return lines to be made back to the mk3 rack.
Bit of a guessing game without a gearbox in place but have plenty of room as it turns out.


Got the ABS unit in and started thinking about brake lines to the wheels, engine bay fuse box and wiring. Little did I realize at this point how much work the wiring would become, it was quite important to finish as much as possible before the engine went in.
No room in rain tray for the ME17 ecu apart from where the stock mk2 ecu would have lived on the drivers side but my TSI engine harness wasn't going to reach that far. Lengthening all those wires just wasn't going to happen so another solution was required.
Also looked at putting it inside the car and if I hadn't fitted A/C that would have worked but with that big AC box in the way there's no room there either.
Ran the Mk2 wiring for the headlights and stuff I needed through the RH frame rail to hide it away. Not a full tuck but just tidy up an otherwise messy look.
It was starting to look like I had no choice but to lengthen the engine harness.......

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 #61 on: November 15, 2020, 08:48:45 am »
A new day and more problems to solve, with the battery box in I spotted an opportunity. Quick measure I knew it would work so I set about attaching the factory ECU cradle to the bottom of the battery box. Perfect spot of the ecu, all the wiring more or less works out and its all hidden away making use of otherwise wasted space. Couldn't be any better if I'd planned it.
Power steering lines to come out again to have the ends crimped but they fit nice, starting to get pretty excited for engine install which isn't far away.

Onwards to the front suspension, new wheel bearings in and even though the front brakes were ok but had a slight judder I decided to bin everything and get new 8L S3 rotors with some new Mintex pads I already had.
New Koni sport adjustable dampers and harvested the Eibach springs from the old set up. The shocks were too long as I found out due to them being Corrado ones, the don't make the yellow Koni for Mk2 Golf as it turns out.
This would turn in to a saga all of its own later on down the track.......but for now I thought all was well.
Repainted calipers back together and on the front end was more or less back together other than drive shafts.
I intended to use all Mk3 abs sensors and reluctor rings, unsure if it would work it was just going to have to be suck it and see approach.

Started putting the rear end together and looking at the rusty rear beam was a let down and the only thing left untouched, nope not going to work.
Removed that, ground the rust off and treated it. New coat of black and some pivot bush inserts. Rear brakes were a bit worn and rusty so guess what, yup in the bin and new discs, wheel bearings and seals.
Koni yellows in the rear as well with the Eibachs I already had. Repainted calipers finishing off the rear brakes. Removed the rear bias valve due to the ABS and Mk3 rear sensors / reluctor rings.
Much better, now absolutely everything has been gone through.
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 coons

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Re: Projekt Golf Zwei
« Reply #62 on: November 17, 2020, 06:31:53 pm »
Only just found this thread - I don't come here often enough any more..

Awesome work John. I think the thing that stood out reading this was that steering wheel - did you hand stitch that thing?? Bloody good on you for attempting that. Looking forward to seeing the remainder of the build.

You and Omar should do a build together. With both of you having such anal attention to detail it would go one of three ways; 1. It turns out amazing, 2. It takes 15 years to complete because of so much detail and complexity, or 3. You kill each other after getting on each others nerves. But I bet the weapon of choice is in immaculate condition. Either way, I'd follow that build thread  ;D
Mk3 Golf 1.8T
Honda GB600 Cafe Racer

Offline 80 Vert

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Re: Projekt Golf Zwei
« Reply #63 on: November 17, 2020, 09:56:24 pm »
Yeah hand stitched, took bloody ages. Have a new (old) steering wheel coming which also needs recovering but it's a lot more complex. Looking forward to doing that.
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 #64 on: November 22, 2020, 09:58:33 am »
One of the last engine issues to resolve was the wastegate actuator, since I'd cut off the turbo outlet and rotated it 180deg it now lived where the actuator can used to be. Even looked at lengthening the rod to place it further out but the chassis rail and strut tower are both in the way.
With the engine and gearbox on the bench the solution was simple in the end, place the wastegate actuator at the gearbox end of the engine.
Modify the wastegate on the turbo so that its operation is reversed now that the actuator is pushing / pulling from the opposite direction.

Battery tray and ECU in for now to start on the car side of the wire harness. The wiring was a mission, really no other way to put it.
Both the brake and clutch switches are on the firewall and I must have checked these 3-4 times as they will be near impossible to change if wrong once the motor is in.
A lot of the wiring couldn't be finalized length wise until the engine was in and the whole A/C electrical still needed figuring out as well.

Engine time, hopefully the final install.
Getting it in and bolted up was pretty sweet, looks at home in there. With the suspension already complete it became a roller fairly quickly allowing me to crack on with the wiring towards getting it started for the first time.
I'd sent the ECU to the US months earlier to have the Immo defeat done and on its return had put this in my MK6 GTI to confirm it worked so I knew that part at least was going to work.
Front cross member on the drive line is in.
A/C pump back together with a new pressure control valve, new drier on the condenser and modified lines I'd figured out at the fabrication stage.



« Last Edit: November 22, 2020, 10:02:56 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 #65 on: November 29, 2020, 11:01:16 am »
With the engine in the rest of the exhaust could be finished and installed, things are really starting to come together and a first start is not far away.
Plugged in VCDS to check the ABS for wheel speed and the unit was registering a reading spinning the wheels by hand, so far so good......I thought. (I would be proven wrong later  ;D)
The exhaust pretty much completes the under side, had heaps of problems bleeding the brakes by myself but finally got a firm pedal. Looking forward to it moving under its own power.

Primed oil and fuel, turned the key and presto first start. All a bit anti climactic really, not sure what I was expecting but there you go.
I was greeted by 2 noises that shouldn't be there which upon further investigation with a stethoscope turned out to be a grumble from a bad alternator bearing and a squeak from the water pump on shut down.
Best to deal with that now since the front is still off. The water pump most likely would be ok with coolant in it but its not worth taking that chance so new water pump ordered and fitted another alternator I had sitting around.
https://i.imgur.com/ZFnoIpa.mp4
Changed tack and took a break from the car to repair the bonnet, when the ABF was fitted they smacked the inner frame with a hammer to clearance it, not going to do here. Needs to be repaired.
Cut that section out of the inner frame then repaired it on the bench, welded it back in and then metal finished it. Going to try and get the inside painted before heading away to the South Island so that the paint can cure while I'm away.



« Last Edit: November 29, 2020, 12:20:59 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