mmdonloaf - Mk1 TDI Rally Car Project

[mmdonloaf]

Ladies and Gents, welcome to my Rally Car project.

Been looking for a good sound 3dr non sunroof shell for months, and finally picked one up on the weekend.

Its a '83 1300 Driver.  Im the 8th owner with the 7th having had it for the last 10 years.  I would put up a pick of it looking a little down in the dumps, but I got so excited i forgot to take one before i started ripping the rear apart last night.  So the pics that would have been my first update will have to the be the first of the car.

So........the plan.........PD powered Rally Car.

• Lightened and stripped shell, multi point weld in cage, DTM wide arch kit
• 1.9/2.0 PD TDI engine, fairly standard
• 6 Speed box if space allows, with LSD, maybe Quiafe Sequi Dog box if enough £Â£Ã‚£
• Custom ECU reusing lumps of the one i will rescue from the PD, if i have the time
• Custom alli boot mounted fuel tank, swirl pot and high cap cooler
• Rear disc conversion and 288 front upgrade, untill i can afford 6 pot callis
• Fully adjustable suspension, custome front top mounts
• Full compliment of strut braces
• Aiming for 300 BHP per ton

Thats the plan anyway, im sure it will get changed and added to throughout the build and how healthy my bank balence is looking.

Havn't really thought about the colour yet, but I am tempted into reproducing the Rheila scheme.



So I'll be looking for panels and other PD related bits and bobs, so if you have any let me know.  Also any wishes of luck or guidance will be greatfully recieved, I'm going to need it!

Cheers

Jon

[mmdonloaf]

Taking the Engine out today, took the crane across to the garage last night.

I promise I'll find the time to put some pics up over ther weekend.

[mmdonloaf]

Found a photo of the car before:



So far:

• Removed doors, bonnet, tailgat, all plastic external trims and windows.
• Removed bumpers and lights
• Taken out rear seats, and carpets, and headliner
• Removed engine, radiator, etc etc.

Think thats about it......

Some pictures from Sunday removing the engine:





And the rear for completeness........


Jobs for the rest of this week:

Drain and removed fuel tank
Take off brake lines and servo
Finish stripping off the interior and dash
Take out the screen i broke in my haste to remove it.

And then start stripping the underseal...joy.

Jon

[mmdonloaf]

Help needed from you lovely people:

In a few months, hopefully 1-2, I will be needing to get the shell re-sprayed.

This if of course after its had the repairs it needs, been seam welded, had the cage fitted and after a trial fit of the engine I havn't found yet.....basically when the shell is finished with berg arches etc.  Hmmmm maybe make that 3 or 4 months

Basically by the time ive shelled out for all the work on the shell, new panels, engine, cage etc etc....money will be tight, and ive seen some figures circa the £4k mark for a full bare metal re-spray.

If anyone can suggest a way to cut this cost...(i'm not work shy).....or can suggest someone who could do it cheaply for me, or purhaps would accept some car sponsorship in return for a discount, I would love to hear from you...pm me.

Also, I'm going to be looking for a 1.9 / 2.0 TDI PD engine, box, front loom, ecu etc in the coming months, so if anyone has some parts or knows of some let me know.

Cheers

Jon

[mmdonloaf]

Just a quick one.....finished stripping the interior tonight.

What on earth did VW use to sound proof the foot wells?  The bit they spray over....some sort of bitument type compound?

Anyway, how best is it to remove it, my wire brush shod grinded isn't touching it.

PM me if anyone can help.

Cheers

[mmdonloaf]

Done a little bit more on Saturday.

Dropped the rear axel and removed the tank.
Removed all the fuel lines and brake pipes.

Only thing left on the car now is steering and handbrake.

I need a Drivers side rear arch repair panel ASAP before it can go to the body shop......(PM me if you can help)

Need to finish stripping the underseal from the wheel arches now.

Some more pictures later in the week.