corys mk2 20vt project

[Cory]

so i bought my mk2 with the intention of doing a 20vt conversion after i finished uni, I've now graduated from my graphic design BA with a better result than expected, worked my fingers to the bone all summer and finally picked up a good donor car last night

been looking forward to, and planning this for a couple of years now, and in no way shape or form claim to be a master engine builder or mechanic, but have learnt a lot over the last 28 months that I've spent with my mk2, and have found that the only way to learn is to get stuck in and enjoy it

so will be spending the next few months ticking parts off of my shopping list ready for the swap 

looking forward to drinking lots of updates 


the mk2 and donor car in question











those leathers might make their way into the mk2 just because there in good shape - holding out for some RS500 recaro's though.

so i have complied two lists of parts that i think ill need and are as follows . . .


DONAR CAR PARTS I NEED

engine + ancillaries
Intake manifold
throttlebody
exhause manifold + turbo
intake tubes from turbo to airbox
exhaust down pipe
lamda sensor + mount
boost control valve
ignition coils
fuel rails + injectors
fuel pressure regulator
bottom radiator hose
heater hoses
air / coolent sensors
engine part of the wiring loom
crank sensor
ecu
keys
clocks


PARTS TO SOURCE

air filter
intercooler - mercedes sprinter
T piece for oil pressure sensors
top radiator hose
k-jet fuel pump and intake lift pump
fuel hoses + clips
engine mounts - G60
fuel / air ratio meter - wide band
1.6 carb cable for throttle
oil temp / pressure gauges and sendors
boost gauge
G60 calipers and carriers
16v hubs
16v servo
22mm master cylinder
intercooler mounts - being fabricated by a friend
gti clocks
radiator - e36 top fill
manifold - qpeng
dump valve 007p


some of the parts i know are not completely necessary but are all upgrades that i want to do

if i have missed anything then do tell me as im sure someone will - i know theres nothing about gear boxes in there yet. im going to be using the 02j from the audi but haven't looked into that side of it in great detail yet. im going to keep the audi shift tower and fit that to the mk2. just not sure about the necessary clutch conversion business yet. but if anyone knows a definitive solution dont hesitate to share it!


also ive just ordered a pair of G60 callipers and carriers
new wishbones and bushes
and some 19mm ball joints
front arb and drop links

ROLL ON PAYDAY

[X4MGS]

 


Look forward to reading the build thread...

[Cory]

so i have been fairly busy ordering parts and getting everything together for the swap and i think im pretty much done now.

i have bought the following,

donor car
G60 callipers and carriers
new wish bones
19 mm ball joints
polybushes for front subframe and rear beam
16v kr fuel pump + lines
lift pump
16v hubs
track rod ends
drive belt
vdo gauges
280mm brake discs
braided hoses
merc sprinter intercooler
g60 front mount
air filter kit
new clutch
wheel bearings
new water pump
22mm master cylinder
new copper brake pipe + t pieces
90 hose elbows
63-51 reducer elbow
hose joiner
6 way fuse box for bay loom
30a relays
vacume hose
some twin core cable
space connectors
plus a few extra little electrical bits to try and keep things tidy

also bought a nice leather sparco steering wheel as it was cheap and will tie in with my interior plans . . .



and a little picture of whats been taking up most of the floor space in my room




new wishbones, bushes, drop links and discs




new grooved/vented discs - my friend has had the same on his mk1 for 5 years - £20 a year is good for me!



so getting the rear poly bushes in the wish bones was pretty easy, but the fronts were a sod, so after a bit of head scratching i employed my D.I.Y bush press. as you can see it was made from a couple of sockets with ratchets + an extension attached, with a rear beam bush bolt through the middle of an axle stand - a bit ghetto but worked a treat




end result



then my bargain gauges with original loom arrived



16v hubs, callipers and carriers arrived shortly after that - callipers and carriers available if anyone wants them cheap



G60 calipers and carriers that will be used - a little grubby



and after a little spruce up and primer



and the end result - not perfect i know, but its not a show car.





so ive been getting the running gear ready for the swap whilst the mk2's been sat doing nothing and ive been waiting for other parts to come . . .


old little brakes, and tired old wishbones + track rod ends. . .







wishbones and anti roll bar now fitted, and awaiting hub/ bearing carriers to come back from the garage. hopefully will be this afternoon. in the mean time im gonna crack on with the track rod ends.



next will be to fit new callipers, discs, braided hoses, and master cylinder. then when the mk2's all put back together, the A3 will be striped and the fun part can start 

[Cory]

brakes all got finished up yesterday, and the mk2 is not it its surgery spot, tomorrow i will be removing the EZ engine 

[Cory]

20vt is now in the mk2 bay!    :grin:i know people say it fits in fine, but its like a glove! im pretty convinced someone on the design team had a time machine . . .

was too dark for pictures tonight. pics to follow when its light again tomorrow

[Cory]

nearly there . . .