Mk1 Redroc racer... building the perfect beast...20.12.17 - gearshifter fitted

[mr.brown]

So, third time round and I pretty much left the car unmolested for a few months before the engine conversion bug bit again. Partly inspired by the purchase of these



Existing TSR 2.1 8v



Gone



With no real time constraints, I wanted to do a "proper" job so had an 020 2Y gearbox rebuilt as a hybrid 02K with Quaife LSD and 4.25FD. And a lightened flywheel thrown in for the hell of it. Work done by Gas N Gears (see Facebook for details)



Painted



Fitted with new Sachs clutch



Dropped in with a KR/ABF hybrid engine. The ABF is a 2.0 16v with 150bhp from factory. Hopefully with the KR head, ITBs and a decent map it should be good for a few more



Continuing the theme of getting it right first time, it would have been silly not to upgrade the suspension



And to keep the flappy bonnet in place



In preparation for the coming wiring fest I fitted a mk2 Golf fusebox holder.



To make room for this little lot

[mr.brown]

No point having the power and weak points in the drivetrain so complete new SKF driveshafts fitted



A big shout out to Jason Moyles aka JMR Clubsport, He's one of the very few people still designing and producing new trick bits for our old cars. What you see here is a combined distributor block off plate and coil pack mount



Close up



JMR front coolant flange - angled further down than factory to clear ITBs/Carbs



JMR front/rear engine mounts also fitted. Rear pictured here



On the subject of ITB clearance, mk3 alternator/water pump pulley set up



Random bits - modified cambelt cover, adjustable Fuel Pressure Regulator, Sytec fuel filter



Just for the sake of a bit more clearance I fitted a Spal fan



I then removed the factory oil/water cooler in favour of a Mocal Oil Cooler and thermostatic take-off



Polo GTI oil filter - again, just for an extra bit of clearance (and also much easier to remove)



Checking some of my previous work - I fitted this sender back in 2004/5



And a new tank went in at the same time. I also drove to Holland to pick up a NOS filler neck. It seems it's done it's job

[mr.brown]

If you've an aversion to wiring, look away no. So here's why I fitted the mk2 Golf Fusebox holder



Four new relays - ECU, Wideband controller, High and Low beams. So, yes, I've brought the headlight relays inside and made a complete new harness from here to the lights with 21st century wiring.

Also, fitted a mk4 era battery top fusebox. As you can see, I've fitted two new power supply wires to the fusebox to replace the single factory one



Dismantling the factory wiring (which was from a mk2)



Starting on the ECU wiring



Bit neater



Injector harness



Nearly there

[mr.brown]

Few more bits added - mk3/4 era expansion tank, Mocal catch can, Wiechers strut brace



Air temp sensor



First electrical test



Started off at 3.5 bar with the G60 injectors but later changed to bigger "Red Top" items and dropped down to 3 bar



Another very trick bit - USRT "Mushmeister"



Got it running on an initial map. Which was enough to get it down to the MOT



I've had this Schroth "quick-fit" harness for years but never fitted it



As part of the next phase in this project, I need to cut down the airbox a few inches

[mr.brown]

I think it's probably safe to say that no other mk1 has had so many looks.

The first



And then (in no particular order)













And now

[mr.brown]

So the reason for cutting down the airbox was so that I could fit this



The horizontal rod goes through the bulkhead



Luckily I found some kit-car vents so I have still have heat-to-feet when I want it (this is a view looking up from the floor)



This is the bracket that has to be mounted to the other side of the bulkhead



Better interior pics

[mr.brown]

And this one.

[mr.brown]

And one for good luck

[mark1gls]

Seems you have been very busy... looks good and I guess it’s a blast to drive?
Is that another Mk1 on your drive?

[16v_coupe]

Got it running on an initial map. Which was enough to get it down to the MOT

I like this new motor, that you put in the Redroc

Wish I could build an ABF/KR hybrid without paying lots money to import the parts here to America or pay high dollar for the bits that are already here

Where did you get these tail lights

[mr.brown]

Seems you have been very busy... looks good and I guess it’s a blast to drive?
Is that another Mk1 on your drive?

It;s not been properly mapped yet so I've been taking it easy - hopefully getting that sorted this week.

The grey car is the "next" project - Belgian LHD write-off to be rebuilt/reborn.

[mr.brown]

Wish I could build an ABF/KR hybrid without paying lots money to import the parts here to America or pay high dollar for the bits that are already here

Where did you get these tail lights

Yeah, that's a shame - KRs are virtually free here and ABFs are plentiful and cheap - for the time being anyway!

The tail lights were Ryan's creation for the Storm I sold him (and bought back from him) many moons ago. The foglight - which would have originally been mounted on the bumper has been put in the reverse light slot (reverse light is not a legal requirement). The white part of the lens has then been sprayed with red tint.

[16v_coupe]

The grey car is the "next" project - Belgian LHD write-off to be rebuilt/reborn.

Looking to seeing this project

Yeah, that's a shame - KRs are virtually free here and ABFs are plentiful and cheap - for the time being anyway!

Guess for now I will enjoy my two 9A 2.0 litre 16v engines for now

A) 88 has a PL head on the 9A with a stock cam set of 195 intake and 215 exhaust

B) 87 has a PL head on the 9A with a cam set of KR intake 215 and 215 stock exhaust.