G reg GT2 - 1.6TD conversion

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DrJ
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G reg GT2 - 1.6TD conversion

Post by DrJ » Thu Jan 09, 2014 11:15 pm

Thought I too should start a build project as I upgrade the Scirocco.

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Initial plans were:

Borrow a mate's selector guide, and adjust the gear selection.
Ditto try to adjust the clutch cable, to get a better biting point.
Replace stereo with replacement period model.
Replace speakers with 6x4s hidden behind original covers.
Replace the pooberg with a Weber.
Replacement heater blower.
4-1 exhaust manifold.
2" exhaust.
Better air filter.
Gti cam.
Better shocks and springs, with a mild hit of the lowering stick.
Polybush all round.
Top and bottom strut braces front and back.
Probably some period alloys like Avus Snowflakes shod in decent rubber.
Port and polish the head.


After a first MOT showed rotten brake lines and cables, they've now been replaced. Otherwise she's pretty solid.
Ianaudia4 kindly offered up a new (old) head unit, as the old one was missing half the fascia.

Time for fitting - Out with the old:

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In with the new... er:

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Irritatingly, the aerial cable's gone walkies somewhere down the back of the dash. Going to dig it out when I wire in new speakers.
Also turns out the clutch problem wasn't the cable but the actual clutch being totally knackered. Replacing this on Tuesday, and hopefully get some pics of her nether regions. Some stuff has turned up or been collected too:

4-1; currently being wirebrushed, before a dose of stoveblack and heatwrap.

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and one of these:

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Last edited by DrJ on Fri Oct 13, 2017 9:13 pm, edited 3 times in total.



ianaudia4
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Re: Project Vega.

Post by ianaudia4 » Thu Jan 09, 2014 11:24 pm

Good to see you making some progress mate, will we see you at some shows this year?


1984 MK2 Havanna brown Storm
1989 MK2 Alpine white Scala injection
2006 Audi A4 3.0TDI quattro (the beast)

DrJ
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Location: Cardiff and Plymouth

Project Vega

Post by DrJ » Sun Jan 19, 2014 5:43 pm

Ian - hope to be, I quite often work weekends, so will plan when I know my rota. A new reg number added to the shows!

The longer I own this car, the more faults I find. Beginning to look like pro-active maintenance has not been carried out in a lonnngg time. She's currently at a VW watercooled specialist in Devon having a new clutch (clutch was dead, not the cable), new CV boots and full service. Other things that have happened:

These arrived-
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So got to work taking out the old, small wonder they didn't work-
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At which point it started raining. I didn't fancy soldering in the rain, so turned to trying to trace a leak.

I think this has developed over the winter with all the heavy rain. I noticed the passenger footwell and the plastic trays next to the fuse box filling with water.
My scuttle it knackered, and I think the seal round the heater-blower is tired, but not convinced that's the origin of all the water.

Stripping out carpet and rotten soundproofing:
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Some very dead and stinking soundproofing:
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Then I noticed this, so potentially a leaky windscreen?
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Finally another question.
Anybody got any idea what this is? Last owner said it might have been an external immobiliser?
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It may link up to these cut wires?
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the edmundator
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Re: Project Vega

Post by the edmundator » Sun Jan 19, 2014 6:50 pm

Yes, that thing on your rear wing will be an immobiliser point.


Register Member 829
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1980 Mk1 GLi
1980 (1976) Mk1 Junior Cup Replica
1982 Mk1 GTI (pending project)
1987 MK2 GTX

ianaudia4
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Location: Central London and Essex

Re: Project Vega

Post by ianaudia4 » Sun Jan 19, 2014 9:44 pm

Indeed, a 80's/90's alarm and immobiliser. Seen quite a few over the years, what were we thinking back in the day?

You mention soldering, are you going to solder the speaker cables? Just snip the old plugs off and crimp on two spades for the new speakers.


1984 MK2 Havanna brown Storm
1989 MK2 Alpine white Scala injection
2006 Audi A4 3.0TDI quattro (the beast)

mark1gls
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Location: Somerset

Re: Project Vega

Post by mark1gls » Sun Jan 19, 2014 10:20 pm

You can buy the small and big spade connectors from maplins for the speakers, if you need to remove the door card at a later date it's easier to pull the connectors off than unsolder the joint.


Mk1 78 Scirocco GLS 1.6 FR, weekend toy.
Mk1 88 Golf GTi cabriolet 1.8 DX. Daily drive.
Membership No. 323

DrJ
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Location: Cardiff and Plymouth

Re: Project Vega

Post by DrJ » Mon Jan 20, 2014 9:05 pm

Sort of tempted to reinstate the external immobiliser. Might investigate this.
I was going to cut the block off the old speakers and solder them to the new ones. Spades does make a lot more sense. Off to the shops I go.
Pick it up from the garage where it's getting a new clutch Wednesday. Feel like an expectant mother.



mr.brown
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Re: Project Vega

Post by mr.brown » Mon Jan 20, 2014 10:55 pm




stys0n84
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Re: Project Vega

Post by stys0n84 » Fri Feb 07, 2014 8:32 am

Hi drj did you find the source of the leak as I'm having the same problem. It is coming from by the bonnet release but apart from a ropey part on the bottom corner of the windscreen seal I can't see anything.


Start off slow and methodical, that doesn't work so shout curse and hit it till it works.


1255

DrJ
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Re: Project Vega

Post by DrJ » Mon Feb 10, 2014 10:06 pm

Haven't found the source yet. Stripped part of the dash out and it seems to be coming from the windscreen corner. Waiting for a dry day/ mate's garage to have a proper go at it.



DrJ
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Re: Project Vega

Post by DrJ » Mon May 26, 2014 3:06 pm

Been a while since I posted. Money's been tight as my missus decided it was time we bought a house, so the Scirocco's been on the go-slow.
Upgrades:
MOT showed that the brakes were tired.
When I took the wheels off the discs actually looked ok. All got replaced anyway.

The Pagid discs on the left actually came with the car, but one of the pads had a fracture across it. Pagid discs now available for sale if people want, completely unused. Just spares currently
The Brembo's are on the car.
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Cleaning up the carriers:
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All fitted:
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Also been at work on the 4-1. Now heat resistant painted, awaiting heatshielding.
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I've also tracked the leak down to some corrosion around the windscreen. Sealed that up with Tigerseal, and along with one of Joost's thicker trays seems to have stopped the leak at present.
The wet weather and multiple of layers of T-cut have led to blistering on the surface of the car now. Potentially looking at getting a respray.
Anyone who's had it done, how much did it cost you?



DrJ
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G reg GT2 - Parts hoarding!

Post by DrJ » Wed Jan 07, 2015 2:49 pm

Another long pause in upgrades and updates.

Stirling work over the summer as my reliable, economical, grin-inducing daily led to a replacement of both rear wheel bearings. Neither looked like they'd ever been changed. With the deafening bearing roar gone it's left behind a softer gearbox whine. Looks like the replacement 4T diesel gearbox has done plenty of mileage.
With this is mind she's been laid up for the winter away from all that nasty salt while I collect parts.

Having bought the local white wrecked GTX for parts I've built up a tasty pile.
Sitting in my cellar ready to be fitted in the spring pre-MOT:
- Weber DMTL carb
- 4-1 manifold
- polyurethane gearbox mounts
- polyurethane engine mounts
- DX GTI cam
- new rocker cover gaskets
- usual full service gubbins

Gearbox will be rebuilt at this point to. The really tall 5th is just too good for cruising to bin.

Updates with pictures when it all happens.
Last edited by DrJ on Fri Jan 09, 2015 5:25 pm, edited 1 time in total.



mark1gls
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Re: Project Vega

Post by mark1gls » Wed Jan 07, 2015 4:14 pm

I would avoid using the polyurethane engine mounts, they can make the car very rattly inside with the engine vibration going straight into the cab, I've not used the my self but lots of people do seem to change back to rubber mounts after a couple of months of rattles.

I could be wrong it really depends on the quality/make of the mounts.


Mk1 78 Scirocco GLS 1.6 FR, weekend toy.
Mk1 88 Golf GTi cabriolet 1.8 DX. Daily drive.
Membership No. 323

DrJ
Posts: 81
Joined: Mon Jul 22, 2013 5:01 pm
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Location: Cardiff and Plymouth

Re: Project Vega

Post by DrJ » Wed Jan 07, 2015 4:20 pm

That sort of echos what I was thinking. I'll definitely use the gearbox mount, but may just replace the engine mounts with decent rubber ones.



mr.brown
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Re: Project Vega

Post by mr.brown » Wed Jan 07, 2015 4:39 pm

Motor mount options:

1. Standard 8v mounts
2. Scirocco 16v mounts - also marketed as HD mounts -replicas here http://www.ebay.com/itm/VW-Rabbit-Sciro ... 0298866026
3. BFI Stage 1 (yellow) - http://store.blackforestindustries.com/ ... 1pem3.html
4. BFI Stage 2 (green) - http://store.blackforestindustries.com/ ... 2pem2.html
5. Prothane/Bugpack (Red) - these are the crazy hard ones - not for those with fillings or implants.

I'd go for option 2 every time :-)