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General => Members rides => Golf mk2 => Topic started by: th3_f15t on 01 March 2016, 23:01

Title: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 01 March 2016, 23:01
Before I begin, here's a little back ground on my past Golf projects.

1991 Golf GTI 8V (Bought 2009 / Sold 2010)
http://www.golfgtiforum.co.uk/index.php?topic=126450.msg1122127#msg1122127

2007 Golf GTI 2.0TFSI (Bought 2011 / Sold 2015)
http://www.golfgtiforum.co.uk/index.php?topic=258812.0

2012 Golf R 2.0TFSI (Bought 2015 / Current)
http://www.vwroc.com/forums/topic/10091-th3-f15ts-12-golf-r-codename-viki/

And now to the latest adventure. A 1989 Golf GTI 16V, in Tornado Red, 3 door and a familiar sight to some of you on this forum:
http://www.golfgtiforum.co.uk/index.php?topic=273010.0

So here's how she currently sits with me:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/IMG_20160206_163525_zps3ln9p7sz.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/IMG_20160206_163525_zps3ln9p7sz.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/IMG_20160206_163541_zpsyyaaegil.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/IMG_20160206_163541_zpsyyaaegil.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/IMG_20160206_164110_zpsvmzabmyq.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/IMG_20160206_164110_zpsvmzabmyq.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/IMG_20160206_164142_zpsyidqnibf.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/IMG_20160206_164142_zpsyidqnibf.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/IMG_20160215_123223_zpsrwkufhmf.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/IMG_20160215_123223_zpsrwkufhmf.jpg.html)

The plan is really a full strip down restoration to completely finish off all the hard work the previous owner put into the car. Also, despite coming with the factory BBS body kit I've gone and purchased a new-old-stock Kamei X1 body kit:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/Kamei%20Kit_zpsx5qrr3zx.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/Kamei%20Kit_zpsx5qrr3zx.jpg.html)

To give you some idea of the finished result, check out this:
http://vagplayers.com/crew/pele/

So for now I'm working on my plans and getting the required parts together to make her into something special. It's the perfect Mk2 Golf in my eyes but it needs some refinement to be my dream Golf GTI. This will be a long, testing, expensive, roller-coaster of emotions trip but I think after 7 years of learning and bettering my skills, I'm ready...
Title: Re: 89 Golf GTI 16V
Post by: jv on 02 March 2016, 12:03
Well, if you can get it looking like your inspiration this should be pretty special :cool:
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 02 March 2016, 12:35
Thanks mate, I won't be going so show-car on the interior. Probably a set of Mk3 Golf Recaro seats (front and rear) and the door cards and the pillar trims all re-trimmed in leather/Alcantara with some LED upgrades here and there. Nothing more than OEM+ really, want to retain everything that makes a Mk2 Golf what it is.

Also looking at tuning the 2.0 9A engine that's under the bonnet, I know you can get easy power from a 1.8T conversion but that ruins the OEM+ theme I'm running with. Might send the engine to TSR Performance for their Snetterton tuning package, exhaust manifold and a Milltek system (ceramic coated for better performance).

Handling is the only area I may stray from the OEM vibe, looking serious at the latest Air Lift Performance 3P/3H kits, they look seriously impressive and would suit my situation ideally. Except for the price...
Title: Re: 89 Golf GTI 16V
Post by: vw_golf_nutter on 05 March 2016, 14:39
will be following your progress and wish u the best of luck with her, although it seems you wont need it, your planning is going well i the early stages so im sure she is going to be one special car!
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 12 March 2016, 10:12
You did a fantastic job on her already, it'd be rude not to finish it to the highest standard. To that end, I've been hoarding parts via eBay and the internet generally this month. So far I have bought:

All new gear linkage bushes, gear stick and knob, gaiter and other repair bits from VW Heritage:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/IMG_20160304_162714_zpschnb8ma2.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/IMG_20160304_162714_zpschnb8ma2.jpg.html)

Replacement gear level surround:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/Gaiter_zps84rbqune.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/Gaiter_zps84rbqune.jpg.html)

Votex centre console:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/IMG_20160311_145638_zpsxciyksda.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/IMG_20160311_145638_zpsxciyksda.jpg.html)

Momo Jet 3 steering wheel, 90's production so I deem it "period correct":
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/IMG_20160309_164504_zpspyb1axzs.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/IMG_20160309_164504_zpspyb1axzs.jpg.html)

And finally for now, a set of refurbished genuine VW Sebring 15 inch alloy wheels:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/Sebring%20Alloy%20Wheels_zpswqacw70l.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/Sebring%20Alloy%20Wheels_zpswqacw70l.jpg.html)

Also currently in talks with TSR Performance and Emerald ECU about building up my 9A engine to hit around 200bhp using a full build engine with a gas flowed head and cams, ITB's and a standalone engine management system. The gearox will get a rebuild as well but with an uprated LSD fitted for good measure as well as an uprated clutch.

Still trying to source a Mk3 Golf Recaro interior at a good price, got one on my eBay watch list that I'm putting a cheeky offer in so that may be purchased soon as well, then it'll get a re-trim as well as the rest of the interior and all new carpets throughout.

Depending on how things go with the Golf R over the next few weeks, I may get round to booking it in with the restoration place to have the shell completely overhauled and refurbished, check out these guys who are about 30 minutes drive from me:

http://www.spikesvintagerestorations.com/

Currently they have a Ferrari Dino, from Ferrari themselves, in for a total restoration. If Ferrari trust them, I reckon I do too! So stay tuned, things are going to get crazy very soon with this! Mk2 Golf GTI of my dreams... I reckon it's possible.
Title: Re: 89 Golf GTI 16V
Post by: hardmonkeys on 13 March 2016, 00:28
 :grin:

Looking forward to this progress!!
Title: Re: 89 Golf GTI 16V
Post by: lemski on 13 March 2016, 17:41
This sounds like its going to be a nice little mk2
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 19 March 2016, 18:16
Made a start on rebuilding the gear linkage today and replacing all the worn bushes. Dismantled the bits:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_01_zpsxhkdneck.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_01_zpsxhkdneck.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_02_zpsn1pu0wpz.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_02_zpsn1pu0wpz.jpg.html)

Got happy with a wire brush attachment on a drill:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_03_zpsrigmpegv.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_03_zpsrigmpegv.jpg.html)

It'll get a proper clean when it gets removed from the car for a rebuild. May clean up a little more while I'm working in the area just for the sake of it, also need to make sure I can open the gearbox oil nut so I can refresh the oil at least as I want to make sure it's as well looked after as possible seeing as the gears themselves will be re-used. All the bits from the linkage on the bench:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_04_zps9ztfu0x6.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_04_zps9ztfu0x6.jpg.html)

The metal brackets are all going to get wire brushed/blasted down and painted gloss black for a bit of corrosion protection. The big orange bush is totally shagged, I'll get pictures of it tomorrow! But there's not much of it left...
Title: Re: 89 Golf GTI 16V
Post by: Waspy on 20 March 2016, 15:55
So happy to see this back in a forum members hands (and even better someone as capable as you).

Good luck man!

I thought nutter had done the linkages? Must be remembering wrong
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 20 March 2016, 17:20
Thanks man, appreciate the kind words. She did a ton of work but the linkage wasn't one I don't think, judging by the amount of built up dirt on it. It's one of those "little" jobs you don't get round to when you're rebuild the entire body of a car... :laugh:
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 23 March 2016, 19:48
Yeah, definitely not done the linkage! :laugh:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_05_zpsjzd8h7gc.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_05_zpsjzd8h7gc.jpg.html)

No wonder second gear is almost non-existent! All the other bits for the bin (so far):

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_06_zpsrlgcxddd.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_06_zpsrlgcxddd.jpg.html)

And now just to clean these bits up, fit new bushes and rebuild:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_07_zpspsvw7jxl.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_07_zpspsvw7jxl.jpg.html)

Can't be arsed to paint them this time round, will do it after I remove the engine.
Title: Re: 89 Golf GTI 16V
Post by: lemski on 23 March 2016, 20:32
 Better than some linkages though.

Good work so far though
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 01 April 2016, 19:21
Got the shot blaster back in action in the workshop so decided I would paint the brackets while they're off the car. Blasted down:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_08_zpsdxuaqmpk.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_08_zpsdxuaqmpk.jpg.html)

Prep'd for painting:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_09_zps9gmawe9e.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_09_zps9gmawe9e.jpg.html)

Primed:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_10_zpsk5hifnug.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_10_zpsk5hifnug.jpg.html)

Gloss black:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_11_zpsoxkvuroo.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_11_zpsoxkvuroo.jpg.html)

Not the best spray job in the world but it'll do for now. Likely I'll re-do it when I do the full tear down. Building it back up:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_12_zpssvtofttt.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_12_zpssvtofttt.jpg.html)

Many hours more than it should of taken me, it's all done:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_13_zpsrp7qtnh3.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/Gear_Linkage_13_zpsrp7qtnh3.jpg.html)

The car is up on axle stands currently so couldn't really drive her but the feel of the shifts is completely changed. Second gear is exactly where it should be, every gear is precise and smooth and the feel is lovely with the weighted shifter. I've got to do the interior end of the gear shift system now as it's held together with elastic bands currently!

Plans now mainly focus on getting the car mechanically sorted and perfect, then I'll tear her right down and do a full ground up restoration. Need to know that the mechanicals are solid before spending huge cash on anything else.
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 22 May 2016, 22:50
Been rather quiet on the GTI front lately as I've been working on sorting out the 6R. Pretty much got her all done now so it was high time to get back on track with Faye. First thing I did was refit the wheels, lower her down and crack the hub nuts off. Breaker bar and a 5ft pole is the trick here, those things are welded on! But got both off now, so jacked her up on axle stands on all corners:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_01_zpsr4wwyk2i.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_01_zpsr4wwyk2i.jpg.html)

Decided that I wanted better access to the gear box selector housing so removed the exhaust, which I want to replace with a different system anyway so made sense to strip it off:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_02_zpskpto0eq4.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_02_zpskpto0eq4.jpg.html)

Wasn't able to get the exhaust manifold off without removing the inlet manifold, which was a bonus as I discovered on of the inlet pipes was broken at the bolt hole. It still sealed properly, but things like that just won't do in this project. Sourced a replacement from the previous owner so will get that ceramic coated and ready at some stage.

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_03_zps4czltvhl.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_03_zps4czltvhl.jpg.html)

After this, was a case of removing things carefully, replacing bolts once things were removed so I wouldn't loose them and labelling any parts of the wiring loom I could, mainly for reference so I can work it out when it comes to putting it back into the car. Tempted to make a new one from scratch myself but make it more modular so it can be removed easier in the future should I decide to change things up. So she currently sits like this:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_04_zpslechkrg0.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_04_zpslechkrg0.jpg.html)

Oil and coolant drained, radiator and fan out, slam panel, grill and lights out, top section of inlet with throttle body removed, exhaust system gone and preparations for draining the fuel from the system are under way. Hoping to have the entire front end stripped down by end of June and smoothed/prep'd ready for painting.
Title: Re: 89 Golf GTI 16V
Post by: lemski on 23 May 2016, 17:25
Good work. Hate smoothing mk2s, hence leaving my bay alone this time around.
Still good progress though bud
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 23 May 2016, 19:04
Thanks man. It's not going to be a show worth smooth bay, just cleaning up and generally making look good. Not deleting things really, although may re-locate the battery and screen wash to the boot and not only will it tidy the bay but is spreads the weight out as the battery sits so far forward in a Mk2. Might be annoying you for some tips on bay smoothing now I know you've done it... :laugh:
Title: Re: 89 Golf GTI 16V
Post by: lemski on 23 May 2016, 19:21
Thats fine mate, it was tedious. I deleted some things that wernt needed. Left the battery but relocated the washer bottle. Im relocating the battery this time just measuring boot up to make sure theres space where I want it as ive got a battery for a s3 in mine
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 23 May 2016, 19:26
I'll have a watch of your progress, will be good to see where others are locating their batteries to. I was thinking of deleting the spare wheel and using the space as a battery well and putting the screen wash bottle to one side with the other housing a subwoofer, ultimately adding more weight over the rear but spreading it out for optimal balance.
Title: Re: 89 Golf GTI 16V
Post by: lemski on 23 May 2016, 19:31
See I was going for sub sunk into the wheel well. Battery pas side and washer drivers side. Hence having to measure up all the sizes. Then dining them away and amp on the back of the seat.
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 23 May 2016, 19:51
That sounds like an ideal situation, but if you get a small enough amp, perhaps mount it in the spare wheel well as sell? Or slightly raise the floor or the boot by building a false floor, sinking the batter and washer bottle into it slightly (adds extra securing methods then)?

Also, does anyone have a good guide for what parts are required to fit a Mk3 Golf power steering rack and pump to a Mk2 Golf? I'm running a 9A engine which is (as far as I'm aware) almost exactly the same fitment as the KR lump.
Title: Re: 89 Golf GTI 16V
Post by: lemski on 23 May 2016, 20:20
There pump goes below the alternator. Should be the brqcket there even without the power stearing.
Rack bolts in the same. Theres not alot of difference between a 2 and a 3 to be honest.
Title: Re: 89 Golf GTI 16V
Post by: lemski on 23 May 2016, 20:21
Youll need different rack mount bushes if you have non pas and are putting a pas rack In though.
Alao if its a wide trqcked mk3 youll have to swap the trackrod arms out unless your going widetrack on the front
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 23 May 2016, 22:08
Thanks for that, will check out my engine block when I'm home at the weekend. I'll use new mk2 track rods and ends regardless, plus new bushings as I'll also refurbish the steering rack itself as I want everything to be like new once it's all bolted back in. Just bagged myself a set of G60 front brakes and got some mk4 Golf rear calipers on order too, so will be refurbishing those at the weekend I think!
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 27 May 2016, 23:00
Got cracking today, continued the taking things off thing:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_05_zpsouowv3gu.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_05_zpsouowv3gu.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_06_zpsbeej80dj.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_06_zpsbeej80dj.jpg.html)

This carried on for most of the day, most things came off with no issues. Only problem I had was one bolt on the passenger wing wouldn't play ball but got the whole wing off by pulling the bolt out with the fitting still attached. No damage done! End result of today's ventures:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_07_zpsxfkzfwcp.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_07_zpsxfkzfwcp.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_08_zpsln94vr8p.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_08_zpsln94vr8p.jpg.html)

Going to clean up the under seal and prime the passenger side so it's protected from rust. The driver's side has a small amount of rot under the scuttle panel, will get a professionals opinion on it over the next week to see the best course of action. I'm off work this next week, although I have a uni exam coming up so I should revise for that really...
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 31 May 2016, 19:03
More stripping it down:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_09_zpspaei2t9l.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_09_zpspaei2t9l.jpg.html)

I had been going away from the original plan of ITB's, but seeing the engine out the car just made me want them again:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_10_zpsdlfakxyl.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_10_zpsdlfakxyl.jpg.html)

Took the subframe off and dismantled it:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_11_zpsrf4rfeas.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_11_zpsrf4rfeas.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_12_zpsyxssyk24.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_12_zpsyxssyk24.jpg.html)

Needs a good clean up:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_13_zps1rj242ry.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_13_zps1rj242ry.jpg.html)

Only just fits into the blaster! Hoping to have it working again soon so I can clean it up and recondition it. I'd rather that as it's the original one but if I can't or the rust has eaten too much into the affected areas I'll source a new, reproduction unit. Swinging to the later option as I'm going to use brand new wishbone with better bushes, new ball joints, refurbished power steering rack with new track rods and ends and refurbished hubs with new bearings.
Title: Re: 89 Golf GTI 16V
Post by: borax on 03 June 2016, 20:43
Nice update. Good luck with it all.There has been a serious amount of work put into this car over the last year or so. Its looking good,keep us updated
Title: Re: 89 Golf GTI 16V
Post by: iain cooper on 04 June 2016, 08:44
great interesting post and brilliant pictures.

keep up the good work !!

giving me some enthusiasm to get my 87 eight valve gti back on the road.

Iain


Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 04 June 2016, 10:40
great interesting post and brilliant pictures.

keep up the good work !!

giving me some enthusiasm to get my 87 eight valve gti back on the road.

Iain

Thanks man. 8V's are highly underrated, you should look at getting the head ported and polished as well as an Audi 50 throttle body upgrade and a good panel filter, you'll really open up the performance of a solid and mid range torque engine. Also find some front hubs from a mk3 Golf and upgrade the front brakes to 256mm versions. If you can get some early mk3 Golf TDI hubs you'll be laughing as they're the same as the mk2 GTI 16V but cost a hell load less but later mk3 GTI 8V ones also work but you'll also need the mk3 Golf ball joint. And some good coilovers and you'll have a killer of a GTI that won't break the bank.
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 04 June 2016, 10:51
So, been pulling bits off all over the place, so far the worst of the rust.rot I've come across is on the driver's chassis leg:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_14_zpsr1h0lf5l.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_14_zpsr1h0lf5l.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_15_zps0pk4zkdi.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_15_zps0pk4zkdi.jpg.html)

After about 4 hours of scraping under seal off I decided I had enough. I'm pretty impress so far with hose good she it under all the paint and under seal... Which there is copious amounts off (you know who you are..!) but I decided that if I want the car done properly then it needs to be done by the professionals. So, I've booked her into a body shop with a great reputation to fully re-do the shell from the ground up.

They're really excited about getting a project back in their workshop rather than just insurance work, they're keen to get me in as soon as they can so we're booked in for 25th June. That gives me just 2 weekends to finish stripping the whole shell down for them... Nothing like a tight deadline to motivate yourself!

Next weekend I plan to get the whole interior out as well as the last of the engine bay parts (wiring, brake servo and heater matrix) and hopefully remove the rear axle and fuel tank. Following weekend will be doors and boot off and final preps as well as building up a trolley to move the shell around on.

All ramping up now, stay tuned!
Title: Re: 89 Golf GTI 16V
Post by: lemski on 04 June 2016, 11:34
Thats not the worst rot ive seen. My old 3 door had to be all rewelded on the inner arch near the scuttle. Good work though buddy
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 04 June 2016, 13:00
I'm not taking any credit for the good condition of this car right now, that goes to the previous owner. Her thread is in the first post, check out how bad it was when she got it!
Title: Re: 89 Golf GTI 16V
Post by: lemski on 04 June 2016, 13:14
Ive seen it and read it.
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 06 June 2016, 13:17
In other news, I'm pretty sure I'm going down the 1.8T route now, been looking into all the various things I can do, but everything just comes back around to fitting the 1.8T engine in one way or another. I will plan to do it a little differently, I would quite like to use an AUM engine (with the K03S turbo) and retain a lot of the Mk4 parts, modifying the Mk2 shell as required. Seeing as it'll be in the body shop and totally stripped back, makes sense to modify any parts at that time in order to fit the full Mk4 running gear.

Looking to get a donor car, then transfer the engine and gearbox, utilising the Mk4 pedals and shifter. Thinking if I can modify the bulkhead of the Mk2 enough I can run not only a full Mk4 hydraulic clutch system, but also the fly-by-wire throttle set up as well. I'll retain the Mk2 subframe and drive shafts along with the Mk2 16V hubs but run G60 280mm front brakes with the Mk4 rear caliper swap and Mk2 Golf coilovers to keep things a little Mk2 like.

It's early days, but seems the easiest way to go considering how far I'm going with regards to the shell. If I weren't, I'd say it was too much but when in Rome and all that... But thoughts and comments are welcome!
Title: Re: 89 Golf GTI 16V
Post by: lemski on 06 June 2016, 15:57
Pm me, might have something for you. ;)
Title: Re: 89 Golf GTI 16V
Post by: borax on 07 June 2016, 05:33
good luck, i would love a 1.8t conversion. You should be able to get a few quid for the original engine as it has been recently rebuilt.

you might as well go the whole hog, as you said in for a penny in for a pound, keep us updated and the Romans :)
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 12 June 2016, 18:54
Smashed another weekend on the GTI, got loads done. When I say loads done, I mean lots and lots taken off...

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_16_zpssiikdg93.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_16_zpssiikdg93.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_18_zps6ifyhmrd.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_18_zps6ifyhmrd.jpg.html)

Fuel tank and rear beam were a pain in the **** to get off, as such I've decided to go mk3 Golf wide track all round, if I'm going to this much trouble then I'm planning on doing the rear beam just once. Will also fit the mk3 Golf petrol tank with a VR6 pump to supply the 1.8T with a healthy amount of fuel.

Onto the interior:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_17_zpsv4noupo3.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_17_zpsv4noupo3.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_19_zpszpqfuoap.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_19_zpszpqfuoap.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_20_zpsnd8p0gpw.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_20_zpsnd8p0gpw.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_21_zpsr2sjuhnj.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_21_zpsr2sjuhnj.jpg.html)

Planning on cleaning up and tidying the original loom as much as possible, deleting what isn't going to be needed and re-making my own custom loom for the audio, if I keep it. If I can fit a DAB antenna stealthy like then I'll do it and get a nice audio package installed. Planning on a caged and clean interior now as well, so will speak to the body shop about smoothing out as much of the interior as possible, making my own custom panels where needed and carpeting the floor just for a little refinement. Just a dash, pedals, wheel, 2 seats, gear leaver and a cage and that's it, bliss!

2 weekends till it goes into the body shop now... Stay tuned!
Title: Re: 89 Golf GTI 16V
Post by: borax on 16 June 2016, 01:52
good luck with this, keep us updated when in the bodyshop. Its going to be good!
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 28 June 2016, 20:16
Spent another solid weekend in the workshop making progress towards stripping her down to a shell...

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_22_zpseagxisoe.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_22_zpseagxisoe.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_23_zpsnlxiqh9g.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_23_zpsnlxiqh9g.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_24_zpsmrpicigg.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_24_zpsmrpicigg.jpg.html)

That was up to Saturday. Came back Sunday morning and cracked on, was determined to have her ready for the body shop as she was due in Saturday morning.

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_25_zpsqqeocbwl.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_25_zpsqqeocbwl.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_27_zps1n7adwrc.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_27_zps1n7adwrc.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_28_zpsbqj4thrg.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_28_zpsbqj4thrg.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_29_zpsnstvzzou.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_29_zpsnstvzzou.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_30_zpsdpajlyio.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_30_zpsdpajlyio.jpg.html)

Quite proud of my work, if I may say so myself! All ready to go, then today my mate texts me these:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_31_zpsenrl48v6.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_31_zpsenrl48v6.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_32_zpsk5ii2imj.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_32_zpsk5ii2imj.jpg.html)

She's now in the body shop and the proper restoration can begin! The floor under the front seats is pretty shot to be honest, planning to replace it but weld in custom mounting points for Recaro or Cobra seats with a bolt on generic frame to suit. That way I can run slightly better chassis re-enforcements while mounting safer seats. Also going to need to repair the rear turrets and wheel arches, but also going to smooth the interior out and delete a lot of stuff, fitting a roll cage and some carpets and that's about it really.

Up front I'll need to repair all the rust, get the custom mounting points for my intercooler and radiator made up and some minor adjustments and smoothing to the engine bay. Relocating the battery to the driver's side where the air box used to go so I can run my intake system for the 1.8T similar to the 2.0 TFSI in design, as this is a really good flow and I'm very familiar with it. Also planning on separating out the electronics of the engine bay and interior as much as possible, so running the essential mk2 Golf systems off the original wiring loom and fuse box but then for the engine I'll use a mk4 Golf engine bay fuse box to keep things as separated as possible. Made a start on the first of the interior looms, because I'm not running rear wind screen wipers or washer, deleted that out the loom:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_33_zpsg8nxdudj.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_33_zpsg8nxdudj.jpg.html)

Got to sort through all this lot though at some point to extract what I need:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_34_zpsejowxapo.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_34_zpsejowxapo.jpg.html)

Decided that was a job for a rainy day. Got on with the interior loom, this one is only going to run the rear lights and fuel tank, and seeing as I'm running a mk3 Golf VR6 tank, it simplified the wiring even more. Plan to separate the looms even more into individual systems then combine them in insulation so that each system can be separated back out easily in the future.

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_35_zpsr5idramr.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_35_zpsr5idramr.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_36_zpsvw4zk19v.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20GTI%2016V%20BBS/RESTO_36_zpsvw4zk19v.jpg.html)

The dash board wiring will remain pretty much untouched bar removing the wires that aren't needed for connecting to engine bay wiring. Will then wrap it all up in modern insulation so it's much more modern looking and protected. Loads of work on that little project alone but I'm excited to say I've already done one job that doesn't involve pulling stuff apart without re-building something! Progress towards the re-build has begun...

Got a VR6 rear beam as well which is in better condition than my GTI one so should turn out much better when done, also got some spacer plates for the stub axles to increase it's width by another 24mm. Sourced some mk3 Golf VR6 front hubs and a mk3 Golf power steering rack and tie rods with ends, so after I get some wishbones I have all the hardware to do both axles. Just a case of cleaning it all up, making it good as new or fitting new parts where required and upgrades too, then having it bolted up ready to fit as a complete axle. If all goes to plan (time and budget allowing) I'll have front and rear axles sat ready to be fitted the same day I get the shell back, I'm aiming to have the car rolling on all 4 wheels within 3 days of getting her back. How hard can a full rebuild from a shell be? :whistle:

Stay tuned, although I'm also planning some tasty upgrades to the 6R too so take a peak at that every now and then for some other progress!
Title: Re: 89 Golf GTI 16V
Post by: lemski on 28 June 2016, 21:40
3 days to build a shell up. Easy mate.
Build the full car in 3 days.
Good progress and well done
Title: Re: 89 Golf GTI 16V
Post by: iain cooper on 28 June 2016, 21:48
didn't realise you were taking it back so far, truly admirable to say the least!

again brilliant pictures and very much motivating.

thanks

Iain
Title: Re: 89 Golf GTI 16V
Post by: th3_f15t on 02 July 2016, 18:08
Bad news... :cry:

The body work guys have had a look over the shell and have said it's really rotten in places and that the previous body work that's been done isn't very good so would need completely re-doing in order to get to the standard where I want it. They said they would do all the work but it would of been at least 3 times my budget so sadly the shell willl have to be sold on to someone who can do a lot of the work themselves to keep costs down.

So now, I need to find myself a replacement Golf (Driver, CL or cheap enough GTI) to use as the base of the project. It's a big blow, but I suspected it may turn out this way. Updates will come when I have a replacement shell to use... The search begins.
Title: Re: Stalled - Mk2 Golf Kamei Edition 1.8T (Hopefully)
Post by: borax on 02 July 2016, 22:00
Gutted for you, good luck finding the next project
Title: Re: Stalled - Mk2 Golf Kamei Edition 1.8T (Hopefully)
Post by: th3_f15t on 14 July 2016, 20:37
So, I've already managed to source and secure a replacement Golf for this project. A 1991 H reg Golf Driver with just 124,000 miles and 5 owners from new. It's pretty much stock apart from the suspension and exhaust. Cosmetically it's in really good shape, just some small areas of rust and a few dents but nothing even near the original Golf! Picking her up in about a week's time from now, but here's some snaps in the mean time:

(http://i.imgur.com/d94dNqe.jpg)
(http://i.imgur.com/Z0Qf0id.jpg)

Also, recently sourced a Digifiz display, a Zender rear spoiler, some mk3 Golf steel wheels that look similar to the ones on there now (but 5 stud ready for my wide track) and some Audi S2 front brake calipers. These, on top of the Kamei body kit, a 1.8T 20v engine swap and a mk3 Golf Recaro interior with my Votex centre console should make for my perfect mk2 Golf ever. Just need to source an Audi 80 electric sunroof and electric mirrors now and I'll have an almost top spec car.
Title: Re: Stalled - Mk2 Golf Kamei Edition 1.8T (Hopefully)
Post by: lemski on 14 July 2016, 20:40
That looks spot on mate
Title: Re: Stalled - Mk2 Golf Kamei Edition 1.8T (Hopefully)
Post by: th3_f15t on 14 July 2016, 20:43
Cheers man, you'll get to see her when you visit... :smiley:
Title: Re: Stalled - Mk2 Golf Kamei Edition 1.8T (Hopefully)
Post by: th3_f15t on 22 July 2016, 16:48
So I'm picking the replacement up tomorrow evening, but the parts collection has grown even more. Firstly, I plan to have a bit of old school fun with the 1.6 engine, so got myself an air filter and a GTI 8V exhaust:

(http://i.imgur.com/mPmYWjp.jpg)
(http://i.imgur.com/saub6TK.jpg)

And also got myself a Zender spoiler (as mentioned):

(http://i.imgur.com/YkWP3Qx.jpg)

Also bought a duckbill front splitter to fit as well, just for a laugh. I think the first stage of body work will involve just tidying it up and treating the small areas of rust not to stop them getting worse, then at a later stage I'll go full on with the Kamei kit. Will also spend time developing my 1.8T engine while I learn some more tricks with the 1.6 engine, which I'm also planning on fitting GTI 8V cams and bottom end to just for a bit of extra fun.
Title: Re: Stalled - Mk2 Golf Kamei Edition 1.8T (Hopefully)
Post by: th3_f15t on 24 July 2016, 23:38
(http://i.imgur.com/iL2aNv1.jpg)

So she's now been in my possession for just over 24 hours. Most people would spend a honey moon period just enjoying the car and getting to know it. Me, well, lets start with this:

(http://i.imgur.com/JM3M06G.jpg)

Made some interesting noises when driving along with more than just me in the car. But logically, before sorting any faults out, modifications are needed. Starters, an air filter:

(http://i.imgur.com/7Dy0zbE.jpg)

Noticed that I have a coolant leak from the expansion tank:

(http://i.imgur.com/CWcdQa9.jpg)

Then I began preparing the new exhaust, first by scrapping off all the labels:

(http://i.imgur.com/REUEtDm.jpg)

Then sanding the whole thing to rough up the surfaces ready for paint:

(http://i.imgur.com/Z0Z3i4C.jpg)

Washed with soapy water to really clean it up as best I can:

(http://i.imgur.com/MDpVEiU.jpg)

And onto spray painting with exhaust paint:

(http://i.imgur.com/UZ3glfq.jpg)

The finished result:

(http://i.imgur.com/KKBnjX9.jpg)

In between layers of paint, decided to fix some of the smaller niggles in the cabin. First, fitted a parcel shelf as the car didn't come with one:

(http://i.imgur.com/PRXZ6bR.jpg)

Bonnet release handle wasn't screwed in, so sorted that:

(http://i.imgur.com/0b4kMii.jpg)

Fixed some loose trim on the dash, but no point in taking pictures as it looks the same as when I started, but definitely stopped most of the rattles now which is awesome. Also fitted my GTI golf ball gear knob and put a cable tie in place to stop the gaiter slipping down the shaft:

(http://i.imgur.com/fS3Acrf.jpg)
(http://i.imgur.com/Yvq9HvB.jpg)

Then decided to attack the current exhaust just so I can drive it without fear of loosing it. Cable tied around the handbrake cable which is never a good idea:

(http://i.imgur.com/7ZnxsGm.jpg)

The hanger point has rusted off so I used 2 jubilee clips to secure it back into position:

(http://i.imgur.com/jaRIqiz.jpg)

It revealed that this exhaust is blowing a fair bit, but there is an MOT advisory for that anyway so I wasn't shocked. Also an advisory for a missing clamp but that'll be negated when I fit the new one. Also on the advisory was a missing seat belt in the rear and the near side head lamp is corroded inside, so I shall look at cleaning them out and if I need to replacing with clear, crystal ones. Other jobs to do next weekend are to fit the 3 door interior from the previous car as these are in really good condition and the front seats currently fitted are 5 door ones. Also, the rear door cards have 6x9 speakers cut into them so they've got to go. Also re-using the gear linkage I re-conditioned from before:

(http://i.imgur.com/VFMdXoV.jpg)

Luckily I never fitted the main shifter rod so that's all unused. While I do the exhaust I'll also do the linkage as without the exhaust in the way life will be much easier. Also, although it'll be some time yet, I have these wheels to replace the current ones:

(http://i.imgur.com/VeZzmDE.jpg)

Almost exactly the same except they are 5x100, ready for the wide track conversion. For now, I think I'm going to keep it really simple in terms of bodywork, delete the door mouldings and possible fit early arches (1984-1987) as these will allow for the wider track but don't have the door mouldings so keeps it clean. Also going to replace the grill with an all black one to delete the red GTI trim, may put chrome trim on instead to compliment the bumpers but undecided. The Kamei kit will happen, but not for a while as I want a slightly different look for a while. Going to also fit a mk1 splitter and the Zender rear spoiler just for some extra eye candy.

At the very end of today, I also took delivery of a PB engine bottom end and camshaft. I'm looking to get the head and manifolds gas flowed and ported and the carburettor worked on (a local specialist says I can re-jet the Pierberg 2E2 carburettor) so decided to have some fun with the rather charming EZ engine. Truth be told, may hold off the 1.8T swap for a while as I really loved the proper old school feel of the EZ and the 020 gearbox. But as you've probably guessed by now, I have a habit of changing my mind!

Edit: This is my 1000th post on the forum after nearly 8 years of membership!
Title: Re: Stalled - Mk2 Golf Kamei Edition 1.8T (Hopefully)
Post by: th3_f15t on 24 July 2016, 23:45
And for now, I leave you with both cars needing a damn good wash:

(http://i.imgur.com/TVEC9hj.jpg)
Title: Re: Stalled - Mk2 Golf Kamei Edition 1.8T (Hopefully)
Post by: lemski on 25 July 2016, 07:22
And this is why I didnt slap a 1.8t in my golf straight away, the rawness of a mk2.
Looks clean, ill have a proper look on Sunday.
Dairplay on the 1St mods though
Title: Re: Stalled - Mk2 Golf Kamei Edition 1.8T (Hopefully)
Post by: th3_f15t on 25 July 2016, 15:41
If I decide to keep the current engine then I'll either sell the 1.8T or fit it to a mk3 Golf as that would be less work, what with them having 02A gearboxes as standard...
Title: Re: Stalled - Mk2 Golf Kamei Edition 1.8T (Hopefully)
Post by: th3_f15t on 04 August 2016, 11:59
Cracked on this weekend again, first job was to remove the terrible exhaust that was hanging off the car:

(http://i.imgur.com/XmDdyd5.jpg)
(http://i.imgur.com/dvBnqRD.jpg)

Used an angle grinder without mercy on it as I have no care for it whatsoever. On taking the downpipe off I realised my GTI 8v downpipe has a different connection face so I'll need to source a correct exhaust manifold and bolt that on before fitting the new exhaust. Which meant while I had the whole exhaust system off, may as well replace the gear linkage as I have that all from the previous Golf:

(http://i.imgur.com/Czku69P.jpg)
(http://i.imgur.com/QtfUexC.jpg)
(http://i.imgur.com/sHflOiC.jpg)
(http://i.imgur.com/pXILliI.jpg)

The linkage wasn't in too bad a shape to be honest, the bushes in the bay were all intact but the shaft looked a little worse off which may explain the lack of 5th gear most of the time! Washed the shifter housing, built it all up and bolted it all back in:

(http://i.imgur.com/6ut923Z.jpg)
(http://i.imgur.com/KAacRIt.jpg)
(http://i.imgur.com/wdTVmVb.jpg)

Feels loads better already and I haven't even been able to drive it yet. Next job on my agenda was to tackle the interior. It came with 5 door seats fitted so the fronts didn't tilt forwards which was a pain, plus the seats had some holes and marks on them but worse of all was the rear quarter panels have 6x9 speakers cut into them. So out it all came:

(http://i.imgur.com/l0aFvTa.jpg)
(http://i.imgur.com/rwxOdRx.jpg)

Fitted the rear panels left over from the previous Golf and hoovered all the carpets and under them too:

(http://i.imgur.com/7S1nAFp.jpg)
(http://i.imgur.com/QgJsQck.jpg)

You can't really see it in the photo above, but one of the anchor points of the seat belts was missing the out casing and looked a bit naff so I fitted the anchor points from the other Golf:

(http://i.imgur.com/IM77p9V.jpg)

Then fitted the front seats. The drivers side is missing one of the plastic guides so it's not as secure as I'd like but the clips are about £2.70 off eBay so will grab a set soon and fit them in:

(http://i.imgur.com/df8Lems.jpg)

Also going to fit the front door cards from the other Golf as they're in better condition again and fit the missing rear seat belt. Need to replace the headlights too as they were also picked up on the MOT advisory sheet as they are corroded inside, then that's all the previous MOT advisory points addressed. Going to give it a good clean as it's covered in tree sap at the minute but hopefully after a few hours work it'll look much better.
Title: Re: Stalled - Mk2 Golf Kamei Edition
Post by: th3_f15t on 10 August 2016, 11:24
So, the more and more I look into it, the more I like the idea of turning my Golf into a 1.8 litre, bike carburettor engined machine. I know I can get power and what not from 1.8T swaps, but if I want power I'll drive my 6R. So the loose general spec I'm building up in my mind is:

Mk2 1.8 GTI 8v PB bottom end
Mk4 1.6 AKL crossflow cylinder head
Mk2 1.8 GTI 8v camshaft
Honda CBR 600 bike carburettors
Mk2 1.8 GTI 8v exhaust system
Mk4 TDI 02J gearbox with hydraulic clutch and cable shift

I'm not after record breaking power or performance, just something that sounds good, is better to look at and just has a proper old school vibe to it. The other carburettor options I've been looking at are Yamaha R1's or FZR1000's. The prior is the most expensive with the later costing a little more than the CBR 600's but both the Yamaha ones are for 1000cc engines which I think may be a little overkill for my plans.

Some thoughts and suggestions would be great, although please try and not comment "just do a 1.8T/VR6 swap" as I really don't want that. It's not about cost, performance or the likes, just want an engineering project for some laughs.
Title: Re: Stalled - Mk2 Golf Kamei Edition
Post by: lemski on 10 August 2016, 17:52
Youll have to jet the carbs anyway so its more the diameter to match the manifold.
Looked a solid golf though mate when I saw it
Title: Re: Stalled - Mk2 Golf Kamei Edition
Post by: th3_f15t on 11 August 2016, 11:59
Cheers man. I need to focus on fitting the GTI cams and exhaust at the very least for now and sorting out the bodywork as best as possible, then look to build up the replacement engine and gearbox. Started also looking into a cross flow head with Weber twin carburettors, although more expensive could be a much easier method of achieving what I'm after.
Title: Re: Stalled - Mk2 Golf Kamei Edition
Post by: th3_f15t on 18 August 2016, 15:54
Got myself a Mk3 Golf GTI 8v exhaust manifold as they're the same as the Mk2 I believe, certainly look like they are and according to part numbers they all work. Cleaned it up and decided to spray paint it to match the rest of the exhaust:

(http://i.imgur.com/oFIjRFI.jpg)

Hopefully going to fit it one weekend soon then take her for a drive around and see how the various bits have improved her.
Title: Re: Stalled - Mk2 Golf Kamei Edition
Post by: th3_f15t on 22 August 2016, 21:54
Small update, fitted the larger side door mouldings and actually prefer them:

(http://i.imgur.com/CYcxhEi.jpg)
(http://i.imgur.com/MF2gvRF.jpg)

Also begun the process of getting the exhaust manifold off so I can fit my GTI one. Although this week I'm focusing on the 6R a little bit more as I have a few issues to sort on her first.
Title: Re: Stalled - Mk2 Golf Kamei Edition
Post by: th3_f15t on 27 August 2016, 21:49
So for various reasons, the 6R couldn't really get worked on in the workshop so I decided to get on with some small jobs. Started by removing the red tape on the grill to return it to the original black one:

(http://i.imgur.com/tGcCRFX.jpg)

I also have some cross hair head lamps to match the spot lights as I really like the cross hair style. Then I carried on with removing the exhaust manifold...

(http://i.imgur.com/QykPkTD.jpg)
(http://i.imgur.com/HMYrKU9.jpg)
(http://i.imgur.com/Pvl3V5Q.jpg)

Well, so the exhaust manifold is off at least. Let me explain my reasoning... I've been planning on fitting GTI cams and bottom end to the head for a while so figured that now was a good time to whip the head off and do so. You can't actually get the exhaust manifold off without removing the inlet manifold and it's all far easier on the bench anyway. Plus now I can give the carburettor a good service and clean up as well as the inlet manifold and cylinder head. Got to get some valve spring compressors to strip it right down, leaving just the guides in and then sending it off to be cleaned, new guides pressed in and skimmed. But that's not going to the engineering firm alone:

(http://i.imgur.com/0yQFiEA.jpg)

Stripped down the bottom end, but the crank shaft bolt is solid on there and there's pretty much no way of getting it off in my workshop so I think it'll go off with the crank and pistons in but I'll tell them that once they remove the bolt, take it out and just leave it for me to work on. Some pictures, it's clear this GTI engine had a hard life...

(http://i.imgur.com/6AU8Ccd.jpg)
(http://i.imgur.com/HBXo5uf.jpg)

Look at those heat spots and the amount of dirt and oil all over the block! The amount of corrosion build up from what was once a bad head is immense, needs a proper clean up in the water channels. There was quite a fair amount of oil left in the block, which I discovered by spilling most of it onto the workshop floor:

(http://i.imgur.com/K784wFJ.jpg)
(http://i.imgur.com/yCrWEoH.jpg)

You can see the stubborn bolt on the left hand side. The plan now is to strip the head down completely, send the head and block off to be stripped and cleaned with various machining work as required before rebuilding the engine back in the workshop with all new gaskets, seals, bearings and bolts. Valves will be inspected and if there's any damage at all they'll be replaced, but this 1.6 EZ engine seems quite well cared for so hopefully just a good clean will do the trick.

That was Friday, today I just mostly tidied up and sorted some other bits out, but I did one small but important job which was to fit new seat runner guides as the driver's seat didn't have them and wobbled terribly:

(http://i.imgur.com/IOIAVMI.jpg)

Then fitted the front door cards to match the rear ones:

(http://i.imgur.com/K3GVBmV.jpg)
(http://i.imgur.com/dSEG26v.jpg)

By the state of the door screws and the plastic skins behind the cards, I don't think those cards have hardly ever been taken off, only when electric windows where fitted to the car by a garage.

(http://i.imgur.com/iQlSya0.jpg)

That's all for now, until I can buy some more tools and get the parts over to the engineering shop for work. Stay tuned...
Title: Re: Stalled - Mk2 Golf Kamei Edition
Post by: lemski on 28 August 2016, 07:52
Doing more ro yours than I am to mine. Fair play mate
Title: Re: Stalled - Mk2 Golf Kamei Edition
Post by: th3_f15t on 28 August 2016, 08:34
I got bored... :laugh:
Title: Re: Stalled - Mk2 Golf Kamei Edition
Post by: Oli_F on 05 September 2016, 22:17
wow, im impressed :shocked:
Title: Re: Stalled - Mk2 Golf Kamei Edition
Post by: vw_golf_nutter on 12 October 2016, 18:26
So im thinking to myself, havnt seen an update on Facebook recently about how the Golf is coming along, I will just check your profile for pics and I find out ive been blocked...

Suspicion rising i have a look through your thread here and now i know why you blocked me....

I have no idea how to feel about this, Im absolutely DEVASTATED to say the very least.
All that hard work, all that money, the dispair, the tears, the favours i had to pull in to get that car to where it was, and its all gone.
I didnt give up on it when it was a flaking pile of orange rot but you have given up on it with a bit of floor rust because my guys welding isnt to a seemingly expensive body works high standard... im totally speechless i really am because i know how proud everyone involved was to of got that car MOT'd and back on the road and I cant forget the feeling i had driving it down those country lanes just listening to that raw engine when i got it back.

That car was never going to be perfect, I did the very best i could with the money i had because i LOVED that car, i so wanted to see it back on the road and enjoyed. I probably loved it far more than anyone should ever love a car but thats why I was so pleased to of found someone like you, you convinced me you were the guy to finish this off but to see it given up on because its never going to be mint is a very hard pill to swallow.

I wish you all the luck with your new one, no hard feelings, but moral of the story clearly is 'never ever sell a car you have put your heart and soul in to', even in the most capable hands there will always be a chance it will be binned for a better one  :cry: :cry: :cry: :cry: :cry: :cry: :cry: :cry: :cry:
Title: Re: Stalled - Mk2 Golf Kamei Edition
Post by: borax on 28 October 2016, 09:09
it is a shame that it never got finished, but dont take it personally. For your own reasons, you also gave up on it
Title: Re: Stalled - Mk2 Golf Kamei Edition
Post by: th3_f15t on 07 November 2016, 07:29
With regards to Facebook, I never blocked you but I actually deleted the whole profile so it's nothing personal. As for what the body shop said to me, it was regarding not just the floor rot but also the rear strut towers (which is unusual for a Golf), the chassis legs where gone as well as other areas of structual integraty. Yeah, it passed an MOT and the work done was good but for where I wanted to go, the shell just wasn't safe enough so it had to be moved on.

I am gutted it ended that way for the car, but sadly it just didn't work out in the end. I left the body shell with the body shop so whether they save it or not is up to them...
Title: Re: Mk2 Golf Kamei Edition
Post by: th3_f15t on 09 January 2017, 17:44
Well, it's been a while but work has carried on slowly over the past few months. I've got the bottom end completely stripped down (bar the pistons and connecting rods) all ready to go off for deep cleaning and the block will be painted when it gets back. Then I'll fit new bearings and hardware before starting to work on the head. The engineering shop I took the bits to weren't that great to be honest and were a pain so I pulled from then and will look at getting someone else to do it who can actually think and do as they're asked...

In other news:
(http://i.imgur.com/XtE46jP.jpg)

I never intended to keep the rainbow interior, which will go up for sale shortly to recover some funds to help cover the costs of these:
(http://i.imgur.com/hBl9pag.jpg)

Set of mk3 Golf colour concept Recaro (fronts are heated) leather seats. Also got a set of genuine Golf Rallye leather door cards to fit as well which is another sweet, hard-to-find item to add to the list of parts. But I need to get the lower seat brackets for the arches and weld in the centre mounting point so the rear seats fit properly. Will also get the wiring loom, switches and relays for the heated seats and get them working as well, then fabricate a custom panel for the centre console to mount the electric windows and heated seat controls in.

Plan now is to get the car built and driving by March in time for a trip to Ultimate Dubs purely so I have a deadline to work towards for motivation.
Title: Re: Mk2 Golf Kamei Edition
Post by: lemski on 09 January 2017, 19:33
Deadlines are useless.
Seats look nice though mate. Like where this is going.

Can you not fit the heated seats into the blank spaces that the back window switches would be in
Title: Re: Mk2 Golf Kamei Edition
Post by: th3_f15t on 09 January 2017, 20:14
Deadlines are useless.
Seats look nice though mate. Like where this is going.

Can you not fit the heated seats into the blank spaces that the back window switches would be in

I know deadlines are useless, but you know, news years resolutions and all that jazz.

I'll be adding in my Votex centre console so will need to make a custom mount as I think the heated switched for the mk3 Golf are horizontal and I'd like to keep that and fill out the space. I need to make a sketch to really show what I'm aiming at, including the dials I'll use as well so you can get a good idea of my thoughts.

And... I'm thinking about VR6 conversions very seriously now, after digging about and looking at how to fit various engines, it's one of, if not the simplest swap in a mk2 Golf and having had an mk4 Golf R32 for a short while I really do love the VR6 soundtrack.
Title: Re: Mk2 Golf Kamei Edition
Post by: th3_f15t on 19 January 2017, 22:15
In case anyone hasn't spotted this yet:

http://www.autofinesse.co.uk/project-unknown-mk2-golf-20vt/

That's a lot more extreme than my plans, but the same bodykit. First time I've seen a UK car in recent years wearing one of the Kamei X1 kits, there's only a few other images of cars with UK plates on Google images so it's nice to finally find someone who's also using the kit.

Bring back the 90's I say...
Title: Re: Mk2 Golf Kamei Edition
Post by: lemski on 20 January 2017, 11:28
To be fair that golf would be at home on my drive. I like when people go against the grain of usual mk2 modifying.

Puts into perspective what yours will look like fitted mate
Title: Re: Mk2 Golf Kamei Edition
Post by: th3_f15t on 22 January 2017, 14:53
Yeah, mine is a bit more "scene approved" but I'm not building the car for anyone else other than myself. The only thing I really don't like on the AF Golf is the red on the seats, a grey/black would of been my own personal choice but then it wouldn't be so in your face which is probably why this car will get lots of social media and keyboard warrior attention over the next year.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition
Post by: th3_f15t on 30 January 2017, 11:22
So about a year ago I exchanged my mk5 Golf GTI for a mk4 Golf R32 and fell in love with the sound of the VR6 engine. Since then I've never been able to shake the need for one in one of my Golfs, and considering the inspiration behind my car also has a VR6 engine I decided that I wanted to go down that route.

So in response to this, I've sourced an Audi BUJ 3.2 litre 24v VR6 engine to fit into this project! For the cost it was just as much to get this engine as it would of been for a 2.8/2.9 12v VR6. I managed to get it delivered and includes the ECU and wiring loom plus all ancillaries which is a massive bonus. Also got the VR6 12v engine mount brackets to fit it into my mk2 using a mk3 Golf VR6 subframe and a VR6 Corrado cross member up front so I can use stock Corrado VR6 engine mounts.

As for the transmission, I've gone and bought an 02M 6 speed gearbox from a mk4 Golf 2.8 4motion. Didn't quite realise it's a bit of a mission to fit and requires some customisation to fit but I'll work my way through it all over the next year. Reading a lot of information on fitting them, but my main issues are that I'm also doing a wide track so info regarding fitting it into mk2 Golfs is out (so looking at mk3 Golf VR6 upgrade guides), also trying to suss out what drive shafts I'll need (either raid the VAG parts bin or get some custom ones) and all the wiring. There comes another issue in that most of the wiring guides talk about linking it to mk2 Golf clocks but I'm planning to use my Digifiz display which I need to find out if that also uses the mechanical speed sensor from the stock mk2 Golf gearbox, or whether I can adapt a mk3 Golf electronic setup.

So yeah, a lot of research and work to carry out now, but not before I finish the 1.8 litre carburetor engine upgrade so I can at least get out and drive the car for the summer. Anyone who knows of good topics to read (regardless of mk2 or mk3 Golf platforms) just chuck the links below so they're all collected in one place.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition
Post by: th3_f15t on 14 March 2017, 20:15
Sold off the door cards I fitted a few posts back so decided to fit up my new ones:

(http://i.imgur.com/SgciNCS.jpg)

Golf Rallye door cards that came with my leather seats. Finish off the interior very nicely for now. Also got my block and internals back from the blasters:

(http://i.imgur.com/F5fZx94.jpg)
(http://i.imgur.com/OIXOvIc.jpg)

Really pleased with how they came out. Just got to get round to building it back up and dropping the 1.8 into the bay so she can be enjoyed for the summer. Missed my UD deadline but nevermind. Currently, my workflow looks like this...

(http://i.imgur.com/oDHAqW1.jpg)

That doesn't include the 6R list of bits to sort either!
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition
Post by: th3_f15t on 28 May 2017, 23:19
So due to moving about a lot and setting up my first home, things have been slow moving with this project. In fairness, things for my 6R have been non-existent but it's not been totally dead in the water with regards to progress. I've been acquiring bits and pieces along the way like all new engine bearings and hardware, the only bits I need now are new piston rings and new small end bearings for the connecting rods. However, I had an itch for a Mk2 Golf in my life and needed to drive one again so I only went and got myself a 1991 Golf GTI 8v big bumper 5 door! Because I got this, it's changed a few things up in my plans with regards to pace of the project.

I decided that rather than put all the effort into building a 1.8 engine to go in, only to then come back out again and sit about doing nothing, I'll use the rebuilt bottom end with a re-built head from the GTI and but it in the actual GTI as an entire engine rebuild, along with reconditioning the gearbox. I also have lots of spare parts and interior trim left over from the first Golf, so using them to sort this GTI out and get it back up to a better state. Think of it as a driving restoration project to keep the need for a Mk2 in my life at bay. So this weekend I gathered up everything and had a bit of a clear out of the workshop:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20Kamei/Kamei_Golf_057_zps5ktpwx4r.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20Kamei/Kamei_Golf_057_zps5ktpwx4r.jpg.html)

So all in, I'm taking the 1.8 litre GTI bottom end, exhaust system, gear linkage and shifter box and spare interior trim away from this Mk2 and donating it to the GTI to bring her back to life. I now intend to rebuild the 1.6 carb engine and get it running so I can firstly certify I know what I'm doing with regards to building an engine and prove it works, before stripping it out and selling it on to make way straight for the VR6/02M conversion. To that end, made a little more progress with the cylinder head off the 1.6:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20Kamei/Kamei_Golf_058_zpsgwbrohgc.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20Kamei/Kamei_Golf_058_zpsgwbrohgc.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20Kamei/Kamei_Golf_059_zpsoligeqgs.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20Kamei/Kamei_Golf_059_zpsoligeqgs.jpg.html)

Pressed in my new valve guides, next stop is to re-grind the valve seats for a perfect fit, rebuild the head up with the GTI cams and put it all back together. I may need to re-borrow the exhaust back from the GTI just to prove it runs but will see how things go. Also managed to strip the pistons and connecting rods right down:

(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk2%20Golf%20Kamei/Kamei_Golf_060_zpszfqoiodk.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk2%20Golf%20Kamei/Kamei_Golf_060_zpszfqoiodk.jpg.html)

Just need to get new bearings and piston rings as well as a final clean of all the old oil and build up before they're ready to be dropped back into the block. Still working out the finer details of how and when I'm going to manage 3 projects (don't forget about the 6R here) but now I'm living in my own home, with a garage, and working just 9 miles down the road for the foreseeable future, things may start happening again, least for 2 out of 3 of my projects! This one is still in Essex and I live in Dorset now...

Yeah, I got some planning to do! Also thinking of starting up a YouTube channel and vlogging the progress of the GTI instead of a written project diary. Because 2017 and all that...
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition
Post by: lemski on 29 May 2017, 11:34
Dorset??? Not that far away from me now mate.
Another mk2... Thats my next plan. Misses wants one so she might end up with a 16v while i build me a 20vt.
Good progress with the head though mate
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 01 June 2017, 08:46
Introducing Hayley, the 1991 Golf GTI 8v:

(https://farm5.staticflickr.com/4262/35661360991_d56db2a9f4_o.jpg) (https://flic.kr/p/WkgNcz)
(https://farm5.staticflickr.com/4241/34952943734_3b4819b1cd_o.jpg) (https://flic.kr/p/VfEYqW)
(https://farm5.staticflickr.com/4260/35661361371_f4cf697f61_o.jpg) (https://flic.kr/p/WkgNj8)

She does have a grill, but it had an eyebrow spoiler on it which was attached with silicon so I've got to clean it all off and re-paint the grill but it's an original part and all the clips are intact so want to save it. It'll get a coat of satin black and a new red pin stripe. Generally she's quite tidy and solid, not as good as Harriet (the other Golf in this thread if you didn't guess) but really not too bad. The main issues are;

Damage to the rear offside:

(https://farm5.staticflickr.com/4238/34952944554_da8bd0edbf_o.jpg) (https://flic.kr/p/VfEYF5)

Doesn't quite run as it should, so needs a tune up:

(https://farm5.staticflickr.com/4116/35661361701_2586387921_o.jpg) (https://flic.kr/p/WkgNpP)

And a list of other jobs I want to do before MOT in 2 weeks from now:

(https://farm5.staticflickr.com/4288/34952945334_441fa007f5_o.jpg) (https://flic.kr/p/VfEYUw)

I got her cheap as it was advertised as blue smoke from the exhaust but on the drive back, with my girlfriend following in the Passat, we saw no evidence of it so I'm hoping to get away with it for now. As mentioned, it'll get the 1.8 litre bottom end I'm building along with the head that's on it being rebuilt and a reconditioning of the gearbox too, but those are further down the line as is the bodywork. Right now, I'm focusing on sorting the exhaust as it sounds like it was blowing and it's too loud for a daily car and the gear linkage before giving it a tune up. I suspect, seeing as this car was going to be a track car at one point, it may have upgraded cams in it as it idles poorly but until I pull the rocker cover off and have a look I don't know. I have a spare GTI 8v camshaft anyway so that may get dropped in there when I rebuild the head. Already pulled the exhaust off:

(https://farm5.staticflickr.com/4282/35661362161_c9fd917372_o.jpg) (https://flic.kr/p/WkgNxK)

And if you remember, I have a stock GTI 8v exhaust I painted already, including the manifold, but because this actually is a catalyst fitted model, I can't use the downpipes. I'm thinking of fitting a completely stock exhaust as a bigger exhaust on a pretty much stock 1.8 8v engine isn't actually too good for the engine (research natural aspiration scavenging to see what I'm on about). Generally going to tidy her up a bit, get her back (or as close to) stock as possible and address the MOT advisories from last year before getting her on the road as my new daily driver.

But don't worry, Harriet isn't going to be abandoned. She just now gets to go straight to the 3.2 VR6, 02M 6 speed widetrack swap...
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: lemski on 01 June 2017, 09:13
Ummm just take cat out. Its a mk2 so the mot tester wont look for one as a rule.
Looks like the twin to my car. So i might bring the golf when i pop by...

Whats the list say i cant read your writting
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 03 June 2017, 09:55
I'll likely chop the straight pipe for now and fit the front silencer I have, effectively make it a connecting pipe/cat bypass. The list is rather long, main points on it are:

Fitting rear trim
Fitting under dash and centre console trim
Gear linkage
Rear wheel bearings
Replace brake lines, fit 22.2mm GTI 16v master cylinder and 280mm front brakes
Sort out the slam panel and bonnet (get rip of the bonnet pins)
General tune up things and service

Mainly focusing on the previous MOT advisories for now, want to give it a clean bill of health.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 26 June 2017, 20:55
Feels like ages since I posted but it's been just 3 weeks. In that time I've cracked on with the car, the joy of having my own place with a garage now! To start, fitted the replacement exhaust:

(https://farm5.staticflickr.com/4231/34952946144_70941ce962_o.jpg) (https://flic.kr/p/VfEZ9u)
(https://farm5.staticflickr.com/4256/35661362551_2ed2d8c4e2_o.jpg) (https://flic.kr/p/WkgNEt)

Got to sort one of the rubber hangers out as I couldn't maneuver the exhaust into place while laying on my back so the exhaust tips foul the rear bumper currently. Also stripped off the grill, threw the damaged spot lights out and painted it:

(https://farm5.staticflickr.com/4254/35661362841_a50562f846_o.jpg) (https://flic.kr/p/WkgNKt)

Need to do some finishing touches but it's now satin black which looks a lot fresher than the stock, faded black plastic. Also got some new crystal spot lights and will get some matching headlights at some point. I managed to fit some of the interior trim left over from the first Golf:

(https://farm5.staticflickr.com/4214/35623943042_50736f4727_o.jpg) (https://flic.kr/p/WgY29w)
(https://farm5.staticflickr.com/4210/35623943562_4fabbdefd6_o.jpg) (https://flic.kr/p/WgY2iu)

So there's also two new rear wheel bearings, two front outer CV joint gaiters and anti-roll bar end links with new bushes waiting to be fitted in order to address all the previous MOT advisories but still need to sort a replacement windscreen. I want to get this car put through with no advisories, which brings me onto the next issue...

It wouldn't start, it fired up and tried to idle but as soon as it did, it died. Very occasionally it's just about hold it for a few seconds but the moment I touched the throttle it died. So I started checking everything out, and when I got to the oil breather, it was FULL of custard. Opened the oil cap to find this:

(https://farm5.staticflickr.com/4254/35661363311_74455e82f5_o.jpg) (https://flic.kr/p/WkgNTz)

Bought it with the seller saying it probably needs a new head gasket as it was putting blue smoke out, but we didn't see any on the drive home. However, it used nearly 2 litres of water but there was no visible sign of loss outside the engine. I confirmed my worse fears:

(https://farm5.staticflickr.com/4206/35623943832_ddefe32236_o.jpg) (https://flic.kr/p/WgY2o9)

It's garbage inside! Literally just water around the valve train and the water was just brown when I drained it. So off comes the head, stripped down and gave it a small clean ready to get it stripped and skimmed:

(https://farm5.staticflickr.com/4255/35793397375_77c59b2bed_o.jpg) (https://flic.kr/p/WwWw1X)
(https://farm5.staticflickr.com/4257/35623944422_203f0b5198_o.jpg) (https://flic.kr/p/WgY2yj)
(https://farm5.staticflickr.com/4216/35661364321_d5af653310_o.jpg) (https://flic.kr/p/WkgPbZ)

Bit of wheel cleaner inside the head and a lot of the burnt on oil can off with just a light once over with a dish brush. Going to "borrow" a lot of the parts from the other 1.8 build to get this one sorted and drivable again, hoping to have the head sorted by next weekend.

The only worrying thing is I can't see any splits of obvious points of failure in the head gasket and the surface of the head appears to be good (waterways seem corrosion free mostly which is a first for me!) but going to get a machine shop to check it over. Hoping that the gasket just failed generally and water seeped in from a few places. Going to drop the sump, change the oil pump for a new one, clean it as much as possible with the block in the car then flush the engine with oil and coolant cleaners then see how it goes.

I'm not going all out on it just yet as I want to use the car for the summer so it's Roadkill style all the way (go watch that show on YouTube if you've not seen it).
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: lemski on 26 June 2017, 21:08
Oik cooler gasket gone letting the 2 pass each other? Head gasket muc
St be gone if hea using water though. Or theres a cracked cylinder head
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 27 June 2017, 17:57
I'm hoping the head isn't cracked, but will investigate the oil cooler as well. Hopefully that's the point of failure...
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 08 July 2017, 12:06
So, been doing bits and bobs to Hayley over the past few weeks, also been acquiring parts I'll need:

(https://farm5.staticflickr.com/4217/35405466080_542abea733_o.jpg) (https://flic.kr/p/VWEgym)

New head and inlet manifold gaskets, 2 oil filters, valve guides, valve oil seals and head bolts. The other bits I need like gaskets and studs I already have in the workshop back in Essex so I'll repurpose those rather than waste them and buy more parts. Also want to grab my standard camshaft, as this one has, as I suspected due to the poor idle, a 272 degree camshaft (trying to confirm brand at the moment). That being said, I did get myself a Dremel for £10 (rather than £40, bargain!) and been reading up on port matching and gas flowing a head so may give that a go, for a laugh...

So that aside, I've prep'd the block face ready and cleaning the piston faces and bores a little bit:

(https://farm5.staticflickr.com/4236/35405465280_e400322fb3_o.jpg) (https://flic.kr/p/VWEgjy)

And now working my way through the valve train. To start, soaked everything in wheel cleaner:

(https://farm5.staticflickr.com/4241/35405464970_5451a407ef_o.jpg) (https://flic.kr/p/VWEged)

Wrap the valve in tape and load into the drill, then use wire brushes and sandpaper to clean them up:

(https://farm5.staticflickr.com/4289/35405465550_50f42ae048_o.jpg) (https://flic.kr/p/VWEgpd)

And the result of about an hours work:

(https://farm5.staticflickr.com/4288/35405464440_009e9bf1b4_o.jpg) (https://flic.kr/p/VWEg55)

Working through the remaining 3 cylinders now as well as cleaning up the head. Will get it professionally milled and new guides in after I've finished going over it with brushes and the Dremel. Got some other bits to show soon, but not been taking loads of pictures as I've been cracking on, but stay tuned...
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 10 July 2017, 18:25
I've always wanted to have a ported and gas flowed cylinder head but never wanted to pay for it. After reading up and getting some advice, decided to have a crack myself. If it goes wrong I can source a new head and use the bottom end that currently sits in the workshop. Regardless, I'll be using a second head on the other bottom end with the 272 degree cam and making a track focused engine, for a laugh. So, some pictures:

(https://farm5.staticflickr.com/4286/35452881100_804e393496_o.jpg) (https://flic.kr/p/W1RhoG)
(https://farm5.staticflickr.com/4288/35452880730_f570956d5b_o.jpg) (https://flic.kr/p/W1Rhhj)

So the general theory, for those that don't know, is to remove factory imperfections and open up more space for air to flow into the combustion chamber, and then allowed it to flow more freely and efficiently out of the chamber via the exhaust. This is a 2 part thing, firstly it's all about shaving tiny but important amounts of metal out of the ports allowing better flow, but the second step will be to "port match" the manifolds, ensuring that they're opened up to match the profile of the head.

Long story short, better flow means better efficiency/power. My aim now is to hit similar power to a 16v GTI but with all the torque delivered much earlier in the rev range. I'll use a stock 8v camshaft for now but may switch to a 268 degree if I find one cheap. The 272 degree is more track focused, which would work well with a flowed head but I'm not planning on sitting at high revs in this car so a bit pointless making it top-end friendly. So onto some shots of work in progress:

(https://farm5.staticflickr.com/4240/35452881510_010624910a_o.jpg) (https://flic.kr/p/W1RhvL)
(https://farm5.staticflickr.com/4278/35452880190_b33755c951_o.jpg) (https://flic.kr/p/W1Rh81)
(https://farm5.staticflickr.com/4214/35452879810_410e51ecd2_o.jpg) (https://flic.kr/p/W1Rh1s)

That's about 3-4 hours work and it's still barely done on the ports I've covered so far! You can see in the last photo though the sort of difference between stock and gas flowed looks like, the aim now is to smooth it right out (maybe even polish it for extra shine) and get the valves re-seated before new valve guides and a skim then back into the car.

All this may seem massive overkill for a "quick restoration" but it's all in the name of learning. I've read a bit about the VR6 engines responding very well to a port and gas flowing session, so you may start to see why I'm going through all this trouble now...

More to come when I get more bits for the Dremel!
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: lemski on 11 July 2017, 13:26
Porting... Ive got a rediculass amount of time in my spare kr head and its no where near done. Even my exhaust manifold has been opened up so it does restrict the gasses with the little bit that may have been in the way. Its a obsession after a while to get the head perfect.

You can also do tb with abit of gain...
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 13 July 2017, 09:07
Throttle body, inlet and exhaust manifolds and the head itself are all on the list of things to be ported. I'm not going too mental at this stage, planning on getting a second head and giving that more of my time. This is just to see if I have the right ideas and what sort of gains you can get but flowing the head.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 15 July 2017, 17:50
Finished off the head, just need to lap the valves in and get new guides and a skim sorted then it's ready to be built up. The finished results:

(https://farm5.staticflickr.com/4324/35100432764_826bec7961_o.jpg) (https://flic.kr/p/VtGTMf)
(https://farm5.staticflickr.com/4286/35100431934_753f8dd55d_o.jpg) (https://flic.kr/p/VtGTwW)
(https://farm5.staticflickr.com/4296/35899528596_7f05215294_o.jpg) (https://flic.kr/p/WGjt8A)

Only when it's running, tuned up and running on a dyno will I know whether there's an improvement, or if I've just done an overkill clean! Going to see how it performs and see where I could of improved and work on another head that'll go onto my bottom end I'm rebuilding.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 31 July 2017, 18:17
This is now a not-so-mini restoration of the GTI, been doing loads of little odd jobs here and there. I've cleaned up the engine bay a bit, got rid of the crappy looking covers on the coolant pipes, replaced the slam panel and painted it red (for a laugh) as a temporary thing, repaired the knock sensor as all the outer insulation had fallen away, repaired the front bumper as the plastic part wasn't on the iron, ordered a load of stuff and painted some bits. I've not taken many pictures, as I've always left my phone indoors but here's some for the hell of it.

(https://farm5.staticflickr.com/4312/35485714403_0775e42f60.jpg) (https://flic.kr/p/W4KyA8)
(https://farm5.staticflickr.com/4312/35485713853_b81cbc8e5b.jpg) (https://flic.kr/p/W4KyqD)

The front end of the car looks a sorry state at the moment as most of it isn't on the car! Tomorrow I'm taking delivery of some more parts, then it'll be a rapid re-build of the front end bar the grill as I need spot light adjustment clips but hoping to get it all back together and ready for just the head to go on, plumed in and connected up then hopefully she'll fire up and time for a test drive.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 03 August 2017, 16:12
Ordered some more parts to finish things off so I can get her MOT'd and driving. Got a new oil cooler to play it safe, injector seals, rubber bung for the breather, pedal rubbers and some gasket sealant.

(https://farm5.staticflickr.com/4353/36307186286_a18087b35d.jpg) (https://flic.kr/p/XjkPys)

Also painting my rocker cover to match the slam panel and front strut brace, although the cover is going to be a wrinkle red finish and not a gloss finish;

(https://farm5.staticflickr.com/4386/36307185556_815eaff1fa.jpg) (https://flic.kr/p/XjkPkS)

And so I rolled the car out into the daylight and revealed this sorry state:

(https://farm5.staticflickr.com/4381/35516041004_cbe08f890b.jpg) (https://flic.kr/p/W7qZCy)

Front bumper put back together and the slam panel;

(https://farm5.staticflickr.com/4351/35954929440_80f2e791fa.jpg) (https://flic.kr/p/WMdpSy)

Forgot to mention I've fiberglassed the hole in the rear bumper, will fill and re-paint it at a later time to fully repair it as well as address the scuffs and scraps on the textured black part if I can. Also need to adjust the position of the back box once the exhaust system is reconnected to the downpipe as it fouls the bumper at the moment;

(https://farm5.staticflickr.com/4343/36307182896_c52edaef26.jpg) (https://flic.kr/p/XjkNy1)

Also managed to bag myself a second cylinder head, camshaft, throttle body and the internals from another GTI 8V which will mostly be used with the other block I'm building back in the workshop unless this head turns out to be junk;

(https://farm5.staticflickr.com/4423/35516039914_9d4b1ce357.jpg) (https://flic.kr/p/W7qZiL)

Cleaned up the throttle body from this car so it's all fresh;

(https://farm5.staticflickr.com/4371/36307181686_5f3d7034d0.jpg) (https://flic.kr/p/XjkNc9)
(https://farm5.staticflickr.com/4382/36307190176_f08ddcae3c.jpg) (https://flic.kr/p/XjkQHw)

A work in progress shot;

(https://farm5.staticflickr.com/4441/35516043324_4e59b618f0.jpg) (https://flic.kr/p/W7r1jy)

Fitted the new oil cooler, cleaned everything up around the area and plumbed it all back together including the radiator;

(https://farm5.staticflickr.com/4348/36307188396_6c9a4b422e.jpg) (https://flic.kr/p/XjkQbQ)
(https://farm5.staticflickr.com/4377/35516042444_997ea42d23.jpg) (https://flic.kr/p/W7r14o)

And fitted the slam panel;

(https://farm5.staticflickr.com/4425/35516042124_d58e9648bf.jpg) (https://flic.kr/p/W7qZXS)

Planning to drive out to Bridgewater tomorrow morning, drop the heads off for some work and once they're back I'll build up the one for this GTI, drop the stock camshaft I've just bought into it and get it running at the very least. Once I get a timing light and hopefully access to an emissions analyser, I'll be able to fully tune it up ready for MOT and maybe getting on a dyno to see what numbers the engine is pushing out.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 10 August 2017, 17:25
Finished off the grill bar the VW badge today, painted the lower trim satin black to match and will get a new GTI badge if she stays long enough, but for now it looks pretty good:

(https://farm5.staticflickr.com/4332/36086975950_224635efd3.jpg) (https://flic.kr/p/WYTbGw)

Also decided the throttle body would look rubbish next to the clean, painted inlet manifold so decided to paint it as well:

(https://farm5.staticflickr.com/4344/36437972576_6d78643f20.jpg) (https://flic.kr/p/XvU8Lu)

Went to fit the bonnet catch the other day but the bolt snapped in the thread, so it's going to be stripped off completely and replaced with a new part, got my eye on a replacement already. Also dropped the heads off at the engine shop, if the one from this engine is knackered (cracked between valves in cylinder 1 and may fail pressure tests) then it'll be straight onto head number 2. Either way, they'll get acid dipped and cleaned, new valve guides and re-cut seats as well as grinding the valves in for perfect fit. That being said, if the initial head is bad I'll ask for the second one back with no valve guides so I can gas flow it properly before getting the rest of the work carried out. Hopefully it'll be driving within the next 2 weeks now, time to research how to set the timing and tune the 8v to perfection.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 11 August 2017, 12:57
Cleaned up the injector wiring loom:

(https://farm5.staticflickr.com/4351/36102482900_75c957c83e.jpg) (https://flic.kr/p/X1fEnJ)

Also fitted the painted throttle body:

(https://farm5.staticflickr.com/4333/35690779453_5c0001c2b8.jpg) (https://flic.kr/p/WnSzhr)

Got a message last night saying that the original head is all good, it's getting sorted now and should be ready early next week, so fingers crossed I can fire her up before Thursday next week. Not got next weekend on Hayley as I'm off to Essex, so maybe some Hariet updates will come soon. Thinking of stripping the rest of the 1.6 engine and gearbox out and starting the process of cleaning the bay up for the VR6 engine.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 14 October 2017, 18:50
Sorry for neglecting this post for some weeks, I’ve not been as busy on the cars as I’d like but I have some progress to update on. To start with, got the head back and into the garage:

(https://farm5.staticflickr.com/4469/37694187081_5194e00f92_z.jpg) (https://flic.kr/p/ZqUyzg)
(https://farm5.staticflickr.com/4493/37694187501_8c666f0345_z.jpg) (https://flic.kr/p/ZqUyGv)

The head had a full pressure test, valve seats re-cut, valves lapped in and new guides pressed in. I’ve also replaced valve stem oil seals, cleaned all the internals and gas flowed the head itself, so this should hopefully be a pretty decent engine when back together!

(https://farm5.staticflickr.com/4512/36983933674_cd479631fb_z.jpg) (https://flic.kr/p/Ym9jYS)
(https://farm5.staticflickr.com/4494/23840994998_208814a584_z.jpg) (https://flic.kr/p/CjKkcU)

Then decided to clean up the head and prep it for painting:

(https://farm5.staticflickr.com/4504/37694187981_1123dbbd95_z.jpg) (https://flic.kr/p/ZqUyQM)

Got some satin black engine paint, didn’t get any pictures of the process of paining, but bare with me, as a few other things happened at the same time. Decided to fit the air feed scoop:

(https://farm5.staticflickr.com/4447/36983931924_99ab08576f_z.jpg) (https://flic.kr/p/Ym9jsG)

And repaired the wiring for the side lights, previous own had re-run it to sit in the indicators which I don’t want at all:

(https://farm5.staticflickr.com/4475/36983932374_77d718c256_z.jpg) (https://flic.kr/p/Ym9jAs)

Soldered and sealed up both sides so should be good now. You’ll also notice in that photo, on the right hand side, the little bit that connects into the wiring for the lights with corroded connections, pulled it apart and repaired it as best I can but may source another one. No pictures, sorry.

Next job to report on is porting out the exhaust manifold. The head-facing side is fine, but the downpipe-facing part was, well, look…

(https://farm5.staticflickr.com/4484/36983932894_dc78a2348d_z.jpg) (https://flic.kr/p/Ym9jKq)

That’s the gasket openings marked on there, the downpipe is that size already but the manifold is a massive restriction it seems. A during shot to show a side-by-side difference in ports:

(https://farm5.staticflickr.com/4488/36983933194_c676dd1897_z.jpg) (https://flic.kr/p/Ym9jQA)

And the result:

(https://farm5.staticflickr.com/4481/37694186541_9706aafe02_z.jpg) (https://flic.kr/p/ZqUypX)

Now faced with a dilemma, do I use stock cams and hope for loads of low down grunt, or do I stick to the 272 camshaft and hope it’s more driveable than a stock head but much better mid-to-top range? Thoughts appreciated.

After this came replacing all the injector seals and caps on all four injectors and cleaning up the fuel rail some more:

(https://farm5.staticflickr.com/4470/23840995778_b36edb6c16_z.jpg) (https://flic.kr/p/CjKkrm)
(https://farm5.staticflickr.com/4457/23840996438_a30386bba4_z.jpg) (https://flic.kr/p/CjKkCJ)

And all this work over the past few posts combines into this:

(https://farm5.staticflickr.com/4507/23840996878_99fcffb42d_z.jpg) (https://flic.kr/p/CjKkLj)

Got to fit it back to the engine, connect the exhaust, wiring, cooling and set the timing then it’ll be time to see if it fires up and runs. Nervous to say the least. Last bit, got some other bits to throw on, Pipercross panel filter being the highlight:

(https://farm5.staticflickr.com/4457/37694185641_09cb9ce90f_z.jpg) (https://flic.kr/p/ZqUy9r)

Update on progress on the brakes to follow, the fronts are getting totally rebuilt, I’ll explain why in the post…
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 21 October 2017, 22:44
Decided today that enough is enough... The engine needed putting back together. Got the head back on the car, bolted and torqued down, put the 272 camshaft back in, lined up my timing marks from when I removed it, re-connected everything and then realised that because I left the downpipe off thinking I could fit it from under the car after the head was on, I realised too late that there's not enough room to put the downpipe on! Luckily I think I can get away with taking the driver's side driveshaft off which should give me the room to fit the downpipe properly.

Progress shots:

(https://farm5.staticflickr.com/4500/37791423616_fef27df2ac_z.jpg) (https://flic.kr/p/ZzuVBf)
(https://farm5.staticflickr.com/4456/37791422986_0b7e89c1ac_z.jpg) (https://flic.kr/p/ZzuVqo)

Still have a few more parts to get hold of to finish it all up but it's pretty much ready to turn the key and see if it even fires up. I'm dead worried I'll of messed the timing up or not tightened the cambelt tensioner properly so may re-check all that before I fire it up for real. Really don't want to trash this engine at this stage.

The reason I went with the 272 cams is that this isn't a daily driver, so a poorer low end and idle doesn't really bother me, plus I'm hoping with the flowed head and manifolds that it'll be OK for low end anyway. It's in the mid to top range where I'd like to see it come alive as I want to enjoy driving this car properly once it's done, as it has a really nice chassis set up at the minute but I may end up re-working that at a later stage.

Hopefully soon I can show a video of the car running and driving under it's own power!
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 29 October 2017, 21:09
More parts:

(https://farm5.staticflickr.com/4444/37312768214_dec6f203c7_z.jpg) (https://flic.kr/p/YRcG2U)

New fuel filter, dipstick housing, indicator (amber) and clear dual filament bulbs, vacuum line in red, some rubber to make gaskets for the front strut brace I have, brake seals, bleed nipples, front lines and disc retaining screws. Also got a new front down pipe:

(https://farm5.staticflickr.com/4508/37991257542_69b9bde504_z.jpg) (https://flic.kr/p/ZTa8gL)

Painted it then thought about fitting it. Removed the front driver's side driveshaft completely and tried to use the old downpipe with the heat shield still attached to work out if it'd work or not. It didn't fit, so I was planning to remove the steering rack to give even more room but decided to try the new down pipes as they didn't need as much room without a heat shield on. They fitted in nicely so quite pleased with only having to remove the drive shaft to get it fitted.

Sadly, went to fire the engine up and it cranks over just fine but will not fire up. Read enough posts on forums to suspect it's an ignition problem so next month I shall be replacing almost everything, that is:

Ignition module (on top of ECU)
Ignition coil
Ignition leads
Distributor cap and rotor arm
Ignition switch
Battery (got a Bosch S4 spare)

I'm not overly worried that it didn't fire, it didn't before I took the engine apart so I suspect that on the drive home from getting the car, some part of the ignition system said farewell and as I parked her up and left it to cool off it decided to leave and go to the special place. If it doesn't fire after replacing all those parts (and probably re-doing all the earth wires for good measure) then I'll be at a loss. It's not the sparks though, those are brand new Bosch super 4 jobs...

As usual, any thoughts or comments greatly appreciated.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 09 November 2017, 14:13
Got some more parts, because why not? I got a new distributor cap, rotor arm and ignition leads as I wanted to eliminate that as a reason for the engine not starting. When I removed the old cap, the centre pin fell off so at that point I suspected the cap was at fault.

(https://farm5.staticflickr.com/4543/38253309402_7d95df7332_z.jpg) (https://flic.kr/p/21hjdah)
(https://farm5.staticflickr.com/4523/38253308902_b7750d5f30_z.jpg) (https://flic.kr/p/21hjd1E)

Certainly looks like the head's been worked over now in my opinion. Bit of an interesting situation when I tried to fire it up though... Certainly turns over a lot better, seems to sound happier with the new parts but still refuses to fire. So here's the situation...

- All wiring is connected and good, checked every earth lead. The battery is fully charged.
- Fuel pump primes for a second or two at ignition, then stops. Fuel is pressured and in the fuel rail (tested). No fuel leaks.
- Tried two different ignition coils now, one from the Driver which I know was working fine and the one that came on the car (which actually looked newer)

The only things I can think of that are stopping things now are:

- Faulty ignition amplifier on top of the ECU
- Timing is way out
- Oil pump blocked

Reasons for the last two options mainly comes down to that I fear I've put the timing so far out it can't fire, but I have no idea what an engine with incorrect timing would sound like when trying to fire up..?

As for the oil pump, I remember driving my brother's Driver years ago when that had a loose oil pickup pipe to the pump and it would stall and die when coming to a stop. I'm wondering if mine is blocked with sludge like everything else was, and can't pump oil around and preventing the engine starting. After cranking it a fair few times, I noticed that there's no sign of fresh oil around the filler cap... I'm going to try heating the oil pan up with a blower heater to get the oil well up in temperature and try again, see if that helps. Thinking if I thin the oil by warming it, it'll also loosen any build up in the pump (if that's the cause of my problems).

Any other suggestions would be most welcome right now.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 10 November 2017, 14:40
Also going to replace the ignition coil with a brand new one and also replace the relay for the fuel pump in the fuse board (currently has an 80 relay in position 12). This should then hopefully be all the common hardware issues sorted.

Also tested spark today, getting a good, bright spark, but looking inside the combustion chamber I can see fluid (fuel) in there? Suggesting that it's flooded or not igniting properly (again, timing out?).
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 11 November 2017, 17:55
Decided to put everything back together now, ready for the new parts that are on order. Fitted the Pipercross filter and air box back:

(https://farm5.staticflickr.com/4529/24467200008_bf532cb187_z.jpg) (https://flic.kr/p/Dh5N91)

Also forgot I bought some screws and holders for the front grill, sadly the screws are too big so will need to find smaller ones. But all in the details:

(https://farm5.staticflickr.com/4570/38282441326_df0549fa90_z.jpg) (https://flic.kr/p/21jTw4Q)

All back together bar some small bits:

(https://farm5.staticflickr.com/4568/38282440346_1ec9da9b77_z.jpg) (https://flic.kr/p/21jTvLW)
(https://farm5.staticflickr.com/4580/38337564701_e302f33460_z.jpg) (https://flic.kr/p/21pL3jR)
(https://farm5.staticflickr.com/4526/26562812779_c25dc7489e_z.jpg) (https://flic.kr/p/GtgmNF)

Did replace the vacuum lines with red silicon ones but can barely see them now, I still need to work out exactly how to plumb all the vacuum lines up so the cold start feature in the air box works as well, just for the sake of sticking close to originality. Currently have a T-piece connecting the front left vacuum port on the throttle body to the fuel regulator and off to a line into the clocks. The other front and rear vacuum port on the throttle body are currently blocked off as these are for a carbon canister which I don't have (I believe, anyway). There is a third fuel line running to something that sits under the air box, there once was a jubilee clipped line coming off it but no idea what it's for..?

Ordered a new ignition coil, fuel pump relay, coolant flanges for the head and new temperature sensor (black one), will get a blue one soon too and double sort the wiring to the connector which looks a bit frayed and exposed. Hoping that next weekend with all the new parts added that it finally fires up and runs so I can begin tuning it up ready for an MOT.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 18 November 2017, 18:36
All the new bits fitted but still doesn't fire so checked the timing. Way out... Whoops! Will correct it properly tomorrow in daylight and then hopefully we'll have a running engine. To be honest, part of a restoration is replacing most bits anyway so a whole ignition system that's been worked over is never a bad thing. Should nip the usual problem areas in the bud for the next decade or so.

The next problem after this is the brake lines where the flexi lines join them, they're corroded and rounded so there's no way to get the lines off. I'm going to replace all the brake lines anyway as the previous MOT says they're all showing corrosion and you can buy the pre-bent lines as a kit (apart from the ones that connect front to rear but got line to make those myself) and will chuck on a new master cylinder, probably a 16v (22.2mm) one just because I can.

Only taken me nearly a decade to take a cylinder head off and put it back on and have a running engine... Progress is progress, right?
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 25 November 2017, 17:24
Reset the timing but still didn't fire. Looked down into the cylinders with the spark plugs out and noticed a strong petrol smell and cylinders 2 and 3 are wet looking inside, so left the plugs out so they can air out and will try again tomorrow.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 16 December 2017, 19:30
Decided to get all new belts as well as a timing belt cover as the original one was damaged and looked rough. Also had to get a new camshaft pulley main bolt as the original one came out so I could inspect everything properly.

(https://farm5.staticflickr.com/4599/39092153041_6cea57d750_z.jpg) (https://flic.kr/p/22yrv9D)

Fitted the new timing belt as well as a new tensioner:

(https://farm5.staticflickr.com/4595/39092152591_a7dcf9e100_z.jpg) (https://flic.kr/p/22yrv1T)

Cleaned up the crank timing gear and fitted with the new bolt:

(https://farm5.staticflickr.com/4687/39092151941_6073ac429c_z.jpg) (https://flic.kr/p/22yruPF)

Also been making an effort to replace as many nuts and bolts with new, stainless steel items in order to make life much easier in the future when this all comes back off again:

(https://farm5.staticflickr.com/4730/39092151291_35ced26a74_z.jpg) (https://flic.kr/p/22yruCt)

All new timing belt covers which include the inner part at the top that sits over the cylinder head and has the O.T. mark for the camshaft on it:

(https://farm5.staticflickr.com/4592/39092150701_8735a4a680_z.jpg) (https://flic.kr/p/22yrusi)

Waiting on some new M8 bolts to arrive so I can refit the lower pulleys as a few of the ones I removed rounded off slightly and are rusty beyond worth saving. Also going to need a new alternator adjustment bolt:

(https://farm5.staticflickr.com/4593/39092150191_7664c52221_z.jpg) (https://flic.kr/p/22yruiv)

Also wire brushed and sanded the main crank and PAS pump pulley:

(https://farm5.staticflickr.com/4726/39092149741_d124b23506_z.jpg) (https://flic.kr/p/22yruaK)

Gave them a spray with Hammerite direct to rust spray just to tidy them up a little bit, will aim to do the water pump at a later date, probably if I replace it. I’m hoping the new bolts arrive Monday so I can fit the new auxiliary belts and try getting the engine running, finally. Been several posts since I first said “tomorrow I’ll fire it up” so I’m giving up making promises to myself at this stage, just being careful and checking over everything twice to ensure I’ve not missed something small but important.

After getting the engine up and running, next jobs to focus on will be the front anti roll bar, braking system overhaul and rear wheel bearing replacement as well as getting tyres for the alloys I want to put on her instead of the snowflakes. Then time for an MOT. Oh, after I finish rebuilding the interior… 2019, watch this space.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 29 December 2017, 17:37
Headline news:

It runs!

Let me go into a bit more detail of the past few days events, as they’re a bit of a mixed bag to say the least. To begin, I decided that instead of re-using the bend, rusty old power steering pump that I’d buy a brand new one. I also ordered a new alternator adjustment bolt as well as some brake line clips and new allen head bolts but those didn’t arrive in time so had to source them from a secondary supplier:

(https://farm5.staticflickr.com/4726/25503162438_0737916b25_z.jpg) (https://flic.kr/p/ERCnFd)

So been out and under the car (more specifically sat in the driver’s wheel arch) and started fitting everything back up and fitting new stainless bolts where I could:

(https://farm5.staticflickr.com/4735/25503161528_d91ac1e6f3_z.jpg) (https://flic.kr/p/ERCnpw)

New belts were going on as well, got the alternator on with new hardware nicely:

(https://farm5.staticflickr.com/4685/38494731945_b6b0aa95f2_z.jpg) (https://flic.kr/p/21DDyEV)

At this point I decided that I needed to confirm the engine would in fact start up and run despite the water pump not being connected up, wanted to justify carrying on with the engine at this point. Got the battery connected, turned the key and after just a few turns of the engine it fired straight up! Was really happy with it, even though the idle was WAY off (about 2500 RPM!) and no air flow meter connected she idled smoothly. Quickly adjusted the idle down to about 1200 RPM and it ran lovely, much better than before when it was lumpy and sounding like a muscle car. There was some smoke coming from the back of the engine where the manifolds are, not sure if it’s stuff burning off (grease, oil etc.) or whether I have a leak at the manifold somewhere on the exhaust side of things but didn’t bother me too much. Then I heard a horrible metallic rattling sound and panicked thinking something had gone massively wrong… Was just the bonnet stay fouling the fan on the alternator! Note to self, work tidy.

So, after this victory I wanted to fit up the water and PAS pumps and get everything running to check for leaks as I also replaced both cylinder head flanges as well as the two coolant temperature sensors (black and blue) for peace of mind. I re-used the old ones as a temporary measure but they leaked badly so stopped cutting corners now and doing things right from the get-go. Ran into a snag when I couldn’t move the power steering pump bracket enough to enable me to fit the new belt. First I tried to undo the bolt at the bottom of the bracket (bottom right in this image):

(https://farm5.staticflickr.com/4591/38494731625_d93058cf21_z.jpg) (https://flic.kr/p/21DDyzp)

It wouldn’t budge at all, totally seized on and going no-where anytime soon. That and the fact the top allen head bolt is rounded means this bracket it practically welded to the block right now, so I removed the pump from the bracket (suspending it out the way securely) and tried wiggling the bracket by hand to free up the threaded bit that connects to the bottom of the water pump bracket…

(https://farm5.staticflickr.com/4647/38494731215_c69ec27b0a_z.jpg) (https://flic.kr/p/21DDysk)

FYI, this isn’t supposed to be like this! Sheared the bolt clean in two, with the lower bit left in the bracket. So now I’m going to have to figure a way to get it off the block and replace everything. Normally, a lot of people would agree this is a set back and a bit of bad news but for me it was just Hayley telling me she wants upgrades (she heard me say I have them):

(https://farm5.staticflickr.com/4634/25503163158_55eae58da5_z.jpg) (https://flic.kr/p/ERCnTC)

This is the Mk3 Golf GTI 8v PAS pump and brackets I got originally for the 1.6 to 1.8 litre conversion on Harriet (the other Mk2 that I still haven’t worked on for ages) which was then destined to be transferred to the VR6 engine but now it looks like it’s going on this car. This means that she’ll now run the upgrade to PAS which is always nice as I’ve read that the Mk3 PAS pump is much better than the Mk2 one so just need to figure out what other hardware I need in order to connect it all up, including replacing the water pump and brackets too.

So there’s more (aren’t you lucky today, reader… or readers? Leave a comment and let me know who’s following this build!). Went to sort out the front brakes too as figured it’d be nice to have the car able to at least roll on its own 4 wheels should the need arise (like to move it outside while I burn off grime and avoid gassing myself out). Gave them a paint and got new seals for them:

(https://farm5.staticflickr.com/4739/38494730675_a7ced32246_z.jpg) (https://flic.kr/p/21DDyi2)

As I was refitting one of the pistons, I must have snagged the dust seal and tore it apart so needed to replace it. Now, logic would dictate at this point that buying a £10-ish set of seals would be cheaper than upgrading to a complete G60 setup (hubs, calipers, master cylinder and servo, the works) but no logic here, decided that it was a sign that I should just fit the G60 brakes and 16v hubs I have sat under the bench and stop wasting time and money on the 239mm brakes. I also have all new pre-bent copper lines for the front setup and I have a 9-inch servo in the pile of parts back in Essex but will need to source a second one as I want to run one on Harriet for my RS2 twin piston brakes I have.

Going to send the calipers off for a professional refurbishment as theses are keepers so worth the investment now. Will also need new tie rod ends as the current ones are seized into the hubs (hammering and WD-40 was ineffective all 10 times I tried) so will take them off with the hubs. Going to replace the ball joints and wishbone bushings too, seeing as it’s all apart and makes sense to refresh everything in one hit. Will also press out the bearings and hubs to freshen the carriers up and fit new bearings and hubs too, no point leaving those out the party.

So that’s all for now but I’m off work for quite a while now while I job hunt for a new career so while I’m not sat sending e-mails and making calls, I’ll be trying to sort Hayley out ready for summer. Summer 2019 that is, at this rate…
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 03 January 2018, 18:34
Couple of pictures of the G60 calipers just before I sent them off for a professional refurbishment:

(https://farm5.staticflickr.com/4685/39475693371_d989f213aa_z.jpg) (https://flic.kr/p/239kfjX)
(https://farm5.staticflickr.com/4642/38767022904_7ebe7dafdd_z.jpg) (https://flic.kr/p/224H8hC)

Originally had these for Harriet to cope with her VR6 engine but shortly after found the RS2 ones so these were spare. Hoping they come back within a few weeks so I can get the car rolling and outside into the sunshine, mainly as I need to sweep my garage floor.

Due to a tight budget lately, I’ve run out of spare cash so no new parts can be sourced for a few weeks, so decided to clean up and beautify some more engine bits. Started with the small inner cam cover:

(https://farm5.staticflickr.com/4645/38767023454_cfcba8ae58_z.jpg) (https://flic.kr/p/224H8s7)
(https://farm5.staticflickr.com/4640/38767023724_9dcccc243a_z.jpg) (https://flic.kr/p/224H8wL)

Alternator mounting hardware was also up for a refresh:

(https://farm5.staticflickr.com/4641/38767024034_658aa765f0_z.jpg) (https://flic.kr/p/224H8C7)
(https://farm5.staticflickr.com/4647/38767024304_df3211a66a_z.jpg) (https://flic.kr/p/224H8GL)

Forgot to get a close one of them painted as I left them drying a bit while I tackled the pumps. Got the pulley off the water pump, took it right back and re-painted it:

(https://farm5.staticflickr.com/4691/39475692451_ec0168808b_z.jpg) (https://flic.kr/p/239kf46)

Will be getting the new water pump as well as a thermostat replacement as soon as I can afford to, I would of re-used the original one but it’s full of corrosion from the head so not worth it. Here’s everything that’s been painted so far:

(https://farm5.staticflickr.com/4637/39445330462_f887044e4c_z.jpg) (https://flic.kr/p/236DCuw)

Got the new power steering bracket painted up too, but this is a work in progress shot as I still need to flip everything and do the other side. Got the other mounts apart from the actual pump, they are going to be a bit trickier to clean up but I’ll find a way. Also have the issue that the Mk3 Golf setup on a 1.8 8v engine isn’t quite in line. I didn’t take a picture but when the PAS pump is mounted up it sits about 1 belt width out towards the chassis leg which is a bit of an issue. I knew you needed some Mk3 brackets but later found the forum post (over on Club GTI) that I read before which says you also need the alternator and mounts, plus different crank pulleys…

Had a bit of a think and so far, from what I can see, a Mk2 Golf GTD PAS pulley is offset slight from the mounting face so thinking of getting one and seeing if mounting it solves my issue as I want to retain the Mk2 Golf alternator now mainly for cost but also because I just painted mine before I discovered the above:

(https://farm5.staticflickr.com/4689/39445329532_73b735158f_z.jpg) (https://flic.kr/p/236DCdu)

Plus, it means no wasted belts and reduces the amount of parts I’ve bought that don’t work with this setup. Worse case I’ll buy replacement Mk2 Golf PAS brackets and hardware and just re-build what was there. Another issue I ran into is that on the bottom of the cast iron block there are two tabs with threads which the bolts for the PAS pump bracket bolt into. One of mine (the outer one) is broken off so only one bolt holds it up! This means, as far as I’m concerned, that this block is on a limited life until the other engine gets built up, then all the ancillaries will get transferred over to the new block and head as well as any lessons learned from this current gas flowed head.

Essentially this is an R&D build right now to see what works and what needs further improvements. Mainly suspect that a 272-degree camshaft will be a bit lumpy at idle and top-end-focused for road use so may source a 268-degree camshaft for the next build. I toyed with a 1.8T swap which may come much later but right now, as the car is still in the “potentially sell again” area of priorities, keeping it close to original is my main goal for resale value.

That being said, my girlfriend keeps telling me we should keep it for the long term and go to town on it… She’s currently working on her Seat Arosa, retrimming all the interior and learning how to do all the mechanicals. We’ve re-done the brakes all round, lowered on Koni dampers and H&R springs, rear anti-roll bar and a load of service work. I’ll see about adding some pictures of her car once we get the new wheels this week and it’s a bit more sorted and once the new seats are in and interior trimming finished some of her work inside. She’s already done an upholstering course using some old Beetle seats and she wants to carry it on further for fun so could make for some interesting updates too.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 17 January 2018, 11:44
Made a start on preparing the power steering brackets:

(https://farm5.staticflickr.com/4698/38842833095_dbd45479b2_z.jpg) (https://flic.kr/p/22bpF1T)

They’re better looking now, need to get a picture of them built up ready to fit. Also ordered a new water pump, G60 thermostat which operates a lower temperatures, flange and an adjuster bolt for the PAS setup:

(https://farm5.staticflickr.com/4630/38842832095_d8601f59c1_z.jpg) (https://flic.kr/p/22bpEHD)

Came with a free water bottle. Nice! Something else arrived too…

(https://farm5.staticflickr.com/4606/38842831535_1ee183b0ea_z.jpg) (https://flic.kr/p/22bpExZ)
(https://farm5.staticflickr.com/4676/38842831145_9868007b4d_z.jpg) (https://flic.kr/p/22bpErg)
(https://farm5.staticflickr.com/4626/38842830345_1d2f4f6555_z.jpg) (https://flic.kr/p/22bpEct)

The look alright, but I have messaged the refurbishment shop with some feedback as the finish isn’t that good to be honest, especially given the price paid for them. I’ve achieved better finishes with a rattle can in the workshop…

Next job is to sort out the brake lines up front, managed to source a 9-inch servo and 22.2mm master cylinder from a Corrado for a nice price so will re-condition that up and fit with the new copper brake lines to give ultimate confidence in the braking system. Also thinking of going for a wide track using Mk3 Golf 4-stud parts to keep the 4x100 stud pattern but increasing the track width by 20mm. Will use spacers behind the stub axles out back to achieve a similar widening.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 20 January 2018, 15:19
Got the GTD pulley:

(https://farm5.staticflickr.com/4656/25924837958_9d0c61491d_z.jpg) (https://flic.kr/p/FuTz7N)

Worked out perfectly, almost… First thing that didn’t go to plan is the pulley mounting face of the pumps. The Mk3 one sits in the opposite was to a Mk2 one, so even with the offset this pulley still sat too far over. So, I used Mk3 Golf brackets with the Mk2 pump but has to grind a small amount off the pump in order for the pump to clear it and spin freely. Also had to double washer the bolts as they’re slightly too long.

(https://farm5.staticflickr.com/4770/25924836428_3fc542d617_z.jpg) (https://flic.kr/p/FuTyEq)

Tensioned up lovely, the Mk3 Golf setup is miles better than the Mk2 one! Finally had the car running and up to temperature today but she smoked badly! My CO2 mixture is well off so needs a full tune up and sorting when I’m finished flushing the various systems through. One round of 20w-50 oil is through, got another one to do before dropping it and the filter and then putting the 10w-40 in which will stay. Got Holts cooling system flush to use (a 2 part treatment) so will report on that when complete.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 08 February 2018, 19:12
Got the pump all fitted up and the engine running nicely:

(https://farm5.staticflickr.com/4605/28375189459_c76853a2c9.jpg) (https://flic.kr/p/Keqgft)

Finished running the flushes through the various systems, now time to address a few other jobs I want to get done. Firstly I noticed the cooling fan seemed to struggle to get going but a spray of WD-40 seemed to fix that. Decided to take it off to look into it and snapped the threads for the bolts on it so it's being replaced for a new item.

Also made a start on overhauling the entire brake system starting with the servo, master cylinder and lines. Removed the stock items:

(https://farm5.staticflickr.com/4697/40155458201_fe42c509d4.jpg) (https://flic.kr/p/24bpdJe)

Has some difficulty with the unions, so decided to just cut the lines with the grinder and use a socket to remove them, was much easier and saved destroying the lines to the rear for now:

(https://farm5.staticflickr.com/4675/40155457711_76f7191580.jpg) (https://flic.kr/p/24bpdzM)

Forgot to get some snaps of the space left behind. All I'll say is I should of done it when the head was off as I needed to remove the entire intake system, including the throttle body, in order to get the servo out. Refurbishing my 9" replacement unit which, being from a 16v Corrado, has the ABS sensor on it so that combined with the front hubs also being ABS ready means an ABS retro-fit is possible sometime in the future should I desire.

Here's the new pre-bent front lines:

(https://farm5.staticflickr.com/4761/40155457911_cb63ae305e.jpg) (https://flic.kr/p/24bpdDe)

Got these off eBay, the seller does them to order pretty much and they're spot on! While on eBay I started ordering a few other bits...

Mk3 Golf 4-stud wishbones, track rods and ends, driveshafts and the other required hardware to fit them along with the brake discs and pads. The hope is everything arrives by the weekend so I can get the car at least able to be rolled out the garage if needs be. Still need to order a master cylinder as the one that came with the servo is too long and has the ports in the wrong position.

Driveshafts arrived within 24 hours which was awesome:

(https://farm5.staticflickr.com/4756/28375189709_876e6a04db.jpg) (https://flic.kr/p/KeqgjM)

Will get some more pictures and update on progress over the weekend.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 17 March 2018, 19:36
Got the 9" brake servo all painted up and fitted, involved taking everything up to the TB off again which was a tad annoying. Also discovered that the pedal sits further towards the firewall when installed with this servo so the 8v brake light switch doesn't work with it, but adapted it for the short term until I get a proper switch:

(https://farm1.staticflickr.com/811/39970253945_81f7d53c54.jpg) (https://flic.kr/p/23U2ZXp)
(https://farm1.staticflickr.com/812/39054287070_8447af2607.jpg) (https://flic.kr/p/22v6qV5)
(https://farm1.staticflickr.com/799/39970255015_513f33eb71.jpg) (https://flic.kr/p/23U31gR)

Then decided that it was a good idea to dismantle the entire subframe and front axle, so got to taking off the engine subframe with wishbones still attached:

(https://farm5.staticflickr.com/4780/39054289410_17e92903fa.jpg) (https://flic.kr/p/22v6rBq)
(https://farm1.staticflickr.com/785/39970253605_100dcfcacf.jpg) (https://flic.kr/p/23U2ZRx)
(https://farm5.staticflickr.com/4794/39970254485_6e12b9c8ae.jpg) (https://flic.kr/p/23U317H)

Stripped off the old wishbones and engine mounts, decided I'm going to replace them with G60 items to firm everything up, plus it's a good upgrade to get done and sorted before a 1.8T swap:

(https://farm1.staticflickr.com/794/39054285640_5d9f6fd21f.jpg) (https://flic.kr/p/22v6quq)
(https://farm5.staticflickr.com/4776/39970252855_f19612ccfb.jpg) (https://flic.kr/p/23U2ZCB)
(https://farm1.staticflickr.com/813/39054284050_c9f859a5d1.jpg) (https://flic.kr/p/22v6q21)
(https://farm1.staticflickr.com/786/39054288130_e1f8e29853.jpg) (https://flic.kr/p/22v6rem)
(https://farm1.staticflickr.com/808/39970252065_38b401a305.jpg) (https://flic.kr/p/23U2ZoZ)

Also got myself some Powerflex black series bushes for the front cross member and the steering rack, seeing as I'm for some unknown reason preparing the car for a 1.8T swap that I never planned to do. Least the 8v engine will be held nicely in place. Also thinking of using Powerflex bushes on the rear beam too just to help things out further, as well as G60 top mounts for the suspension.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 30 March 2018, 16:49
Got some replacement wishbone fitting bolts to freshen everything up:

(https://farm1.staticflickr.com/811/40221962015_e7b82dfa00.jpg) (https://flic.kr/p/24hh4ZH)

Due to impending house move, I've had to put the car back together without getting some of the work I'd of liked done first like powercoating the subframe and roll bar but never mind. It'll all come back off again when I'm set up at my new place. Spent today giving the subframe and roll bar a quick once over to clean off the worst of the rust:

(https://farm1.staticflickr.com/895/40221961515_5bd1b3999c.jpg) (https://flic.kr/p/24hh4R6)
(https://farm1.staticflickr.com/808/27243924878_5921eaaa4b.jpg) (https://flic.kr/p/HvseGJ)

New G60 engine mounts and roll bar bushes on:

(https://farm1.staticflickr.com/798/27243924398_543a31e70a.jpg) (https://flic.kr/p/Hvseys)

Also fitted the Powerflex black series power steering rack bush:

(https://farm1.staticflickr.com/885/40221962375_9b71429e1c.jpg) (https://flic.kr/p/24hh56V)

Likely I'll get more Powerflex bushes sorted at some stage but considering only the rear beam and suspension mounts are now the only older parts, it's not a priority. Also got the old tie rods off after much fighting, subframe fully fitted and engine mounts bolted onto the brackets to the engine, steering rack secured and the flanges for the drive shaft cleaned up ready for fresh grease. Stopped there as needed tea and biscuits.

Over this Easter bank holiday I'm hoping to get the entire front end built ready to go minus tyres on the Sebring wheels. Also need to get hold of a 22.2mm master cylinder and a bottle for the fluid as I can't find my one and then it's pretty much fit and finish the other jobs off before booking an MOT and getting her back on the road.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 08 April 2018, 10:56
Fitted the new driveshafts, front wishbones and roll bar bushes:

(https://farm1.staticflickr.com/890/41271326412_d219772979.jpg) (https://flic.kr/p/25T1ktj)

Stumbling block, I didn't get every part I need, got to order caliper carrier bolts, steering arm gaiters, the master cylinder and reservoir bottle. Also want to strip down and clean the front suspension as it'd be a shame to leave it looking like this:

(https://farm1.staticflickr.com/872/41271326262_ee055f1cf6.jpg)

Hopefully order the parts this coming week and get new tyres fitted to the Sebring alloys so I can take it for a first test drive in nearly a year. (https://flic.kr/p/25T1kqJ)
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 17 April 2018, 17:54
Cleaned up the original brake bottle which came up alright:

(https://farm1.staticflickr.com/874/27652036878_dd20d703d2.jpg) (https://flic.kr/p/J8vVbw)

I did order a new 22.2mm master cylinder and brake bottle but neither will work, and for a simple reason. I bought a Corrado 16V brake servo which has the studs for the master cylinder offset from horizontal like a Golf, so a Golf master cylinder sits at an angle. Luckily I didn't get rid of the Corrado 16V master cylinder so I still am able to put the car back together. Had to bend one of my new brake lines round to fit the cylinder but not fussed about it as the master cylinder has a bleed nipple which is actually a nice touch. Being an ABS setup as well means I could, in theory, upgrade to that one day if needs be. Just nice to know it's there...

Went to fit the front hubs and realised I'd made a bit of a mistake. I ordered the drive shafts for a mk3 Golf GTI, which is a 5-stud and, as I've now learned the hard way, has a different size spline on the outer part of the outer CV joint. So those had to come off, bagged them up as I can use them on Harriet as she's going 5-stud (full VR6 front and rear setup in all honesty) so all is not lost. Also fitted up the G60 brake lines ready to put into the calipers, so currently looking like this:

(https://farm1.staticflickr.com/911/27652036278_35d347ae93.jpg) (https://flic.kr/p/J8vV1b)

Anyone spot a bit of a theme with recent work..? Ordered the right CV joints now, as well as new wheel bolts, spacers for the rear and camber bolts for the front as well to help correct for the wide track and eventual lowering. Need to have this car running and road worthy within the next month as I'm moving house and also want to take the 6R off the road to upgrade to the TTE420 setup.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 05 May 2018, 18:24
Got myself some 13mm spacers and longer wheel bolts for the rear as well as some new bolts for the front:
(https://farm1.staticflickr.com/832/41866479492_b62540f302_h.jpg) (https://flic.kr/p/26MADKj)
(https://farm1.staticflickr.com/946/41192122604_bb4806c591_h.jpg) (https://flic.kr/p/25L1oWq)

Got the passenger side hub built back up:
(https://farm1.staticflickr.com/959/41866479262_8431eed8f3_h.jpg) (https://flic.kr/p/26MADFm)
(https://farm1.staticflickr.com/953/41866479102_1f1e9a1b7a_h.jpg) (https://flic.kr/p/26MADCA)

Looks like a good fit all in all:
(https://farm1.staticflickr.com/977/41866478902_23210d6ce7_h.jpg) (https://flic.kr/p/26MADz9)

Another issue cropped up, the immobiliser in my car fell apart, so had to break out the soldering iron:
(https://farm1.staticflickr.com/972/41866478762_542dd9bfc3_h.jpg) (https://flic.kr/p/26MADwJ)

More on that shortly. First, got myself some extra goodies to fit, a boss kit, a new knock sensor as my old one fell apart, a 16v brake light switch and some new washer jets for the bonnet:
(https://farm1.staticflickr.com/963/41866478452_e82ed6d926_h.jpg) (https://flic.kr/p/26MADro)
(https://farm1.staticflickr.com/974/41866478212_f9dcf6a793_h.jpg) (https://flic.kr/p/26MADnf)

Now back to the immobiliser issue. Refitted the part I repaired but sadly it was not going to play ball. I decided I’d have a go at removing it myself, my logic was that any wires that had been tapped into would match so it was a case of just matching them all back up. Warning, view advised as the next few scenes contain sensitive content:
(https://farm1.staticflickr.com/979/41866477932_9feba3ee79_h.jpg) (https://flic.kr/p/26MADhq)
(https://farm1.staticflickr.com/910/41866477592_280a6c9c75_h.jpg) (https://flic.kr/p/26MADby)

Definitely need to spend some time sorting the interior out, it’s a right mess! Stripped down all the wiring and sure enough:
(https://farm1.staticflickr.com/831/41192123374_1dda5fedc4_h.jpg) (https://flic.kr/p/25L1paG)

One power wire and one earth had been completely cut and another power cable was tapped into, so stripped it all out and re-soldered everything back together and while I was there I untangled all the wiring loom and tidied things up:
(https://farm1.staticflickr.com/967/41192123024_229f8d74de_h.jpg) (https://flic.kr/p/25L1p4E)

Seeing as I was half way there, decided to fit the new steering wheel:
(https://farm1.staticflickr.com/864/41192122824_36ed67085a_h.jpg) (https://flic.kr/p/25L1p1d)

All that’s left now is to replace the rear brake hardlines, discs, bearings and pads then fit the wheels and book an MOT. May of take about 11 months longer than I planned, but she should finally be back on the road. For now, it’s a fond farewell to the immobiliser:
(https://farm1.staticflickr.com/952/27040713527_30f867aa1b_h.jpg) (https://flic.kr/p/HcuJ3K)
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 12 May 2018, 19:06
Got round to fitting the rear brake lines:
(https://farm1.staticflickr.com/970/42017382492_fe4c3287f6.jpg) (https://flic.kr/p/271W4Xb)

Fitted all but one of the hard lines as I ran out of securing clips, decided that it wasn't too bad and seeing I plan to later replace the middle section brake lines that connect the front to the rear, thought I'd just leave it. Naturally, being the type of project this is, that particular hard decided to p*** fluid when pressurised so needed replacing! Decided to get all new flexi lines for the rear too so that only the regulator and the mid-sections as mentioned are left to be replaced for new items. Also finished off fitting the new rear discs, pads and bearings:

(https://farm1.staticflickr.com/971/42017382402_ed693a46d7.jpg) (https://flic.kr/p/271W4VC)

With that all done and sorted, I broke out the auto-bleeder. Love this tool, such a good investment if you want to run your own servicing:

(https://farm1.staticflickr.com/945/42017382202_479be42cb6.jpg) (https://flic.kr/p/271W4Sb)

During the bleeding process I couldn't get the system to pressurise, meaning air was trapped somewhere. I went round 3 times before I remembered the master cylinder I used has a bleed valve on it, so bled that and then immediately had perfect brakes. Also got all new rubbers for the pedals, including the accelorator, which I haven't taken a picture of but really help to refresh the feel of the car. Also had tyres fitted to the Sebrings, went for my now favourites of Avon ZV-3 in a 195 50 R15 flavour. Was worried that when fitted to the car with this choice they'd foul the arches:

(https://farm1.staticflickr.com/949/42017381972_ce8b3571de.jpg) (https://flic.kr/p/271W4Nd)

Needant of worried. Even with a 20mm and 24mm wider front and rear track respectively, they sit beautifully. And so, ladies and gentleman...

(https://farm1.staticflickr.com/955/42017381802_a416c2069b.jpg) (https://flic.kr/p/271W4Kh)

After one year being on axle stands and collecting (a now thick layer) of dust and dirt, she lives and drives! Got to see the garage floor for the first time:

(https://farm1.staticflickr.com/827/42017381562_da0f808866.jpg) (https://flic.kr/p/271W4F9)


Need to sort those slicks out as we're moving out next week and we rent, so can't leave them like that! But grabbed another shot before taking her for a quick spin:

(https://farm1.staticflickr.com/959/42017381372_40a16517be.jpg) (https://flic.kr/p/271W4BS)

Comparing this to the first picture I took of here, seems like little has changed but under the shabby looking bodywork is a world of hurt, emotional turmoil but ultimate pride and joy. Cliché as f*** but I really did smile like a kid with a free ice cream the whole time I was driving her up and down the road to check I had gears and no major failures.

I didn't have a horn at first, realised after taking the boss back off that the little copper spring strip on the column wasn't making connection with the boss itself, so sorted that pretty quickly. One area left to work on now:

(https://farm1.staticflickr.com/963/27191867997_179dbb9f3b.jpg) (https://flic.kr/p/HqRr1i)

Got no wipers front or rear, washer or heater blower in the cabin, it the two relays numbered 72 and 19 that I need to replace. I also have an issue where the coolant level light keeps flashing despite more than enough coolant in the system, suspect it's another relay as I've seen one for sale on Heritage Parts that is for the level monitoring system, but I can't see it on my fuse board. For anyone else who is having issues with relays, this topic over on Club GTI is a god send for identifying relays by the number stamped on them:

https://www.clubgti.com/forums/index.php?threads/relay-numbers.166865/

Just got to sort these issues out, a damn good clean up and then it's off to the MOT centre to get it back on the road fully. I intend to sell off my currently little daily run about and use the funds to get new bumpers and other bits for Hayley now, start tidying her up and making her look a lot better.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 12 May 2018, 19:06
In case you want to compare the above front and side view pictures with the very first two of her:

http://www.golfgtiforum.co.uk/index.php?topic=277127.msg2567330#msg2567330
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 22 May 2018, 12:35
Small update, it was actually (potentially) relay 18 that needed replacing as this controls all the affected systems. Loads of info out there just a Google search away. I replaced the relay as the terminals were covered in corrosion but that didn't work at first. Quick spray of trusty WD-40 and everything sprung back into life.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 30 June 2018, 09:51
I've been busy with moving house recently so things like the cars have taken a slight backseat while I'm sorting everything else out. That being said, I did put Hayley through for an MOT to try and at least baseline what else needed to be done and hoped that she would pass so I could get using her. Sadly it wasn't meant to be, which I will come onto shortly. One thing that's been bothering me is the grill (of all things) as I miss the signature GTI red stripe, so bought myself another one off eBay which wasn't exactly the best condition:

(https://farm1.staticflickr.com/923/42385579584_9bc1169c80.jpg) (https://flic.kr/p/27ztb7U)
(https://farm1.staticflickr.com/840/42385579334_853a9e6e77.jpg) (https://flic.kr/p/27ztb3A)
(https://farm1.staticflickr.com/843/42385578854_6a2d7fd06b.jpg) (https://flic.kr/p/27ztaUj)

It's also missing the two top clips but these really aren't that necessary as it screws into the slam panel anyway and secures nicely. I broke out the glue gun and got to seal it back together:

(https://farm2.staticflickr.com/1810/42385576594_a3b03f7329.jpg) (https://flic.kr/p/27ztaem)
(https://farm2.staticflickr.com/1769/41292675790_0506f11553.jpg) (https://flic.kr/p/25UTKU3)

So onto the results of the MOT. Well, when I was called up by the receptionist for the garage, the term "failed miserably" was used, which was a bit unfair but the list goes like this:

Do not drive until repaired (dangerous defects):
Offside Macpherson strut mounting fractured (5.3.3 (b) (ii))
Nearside Track rod end ball joint worn to the extent there is a serious risk of detachment lock nut lose (2.1.3 (b) (ii))
Offside Track rod end ball joint worn to the extent there is a serious risk of detachment lock nut lose (2.1.3 (b) (ii))
Brake load sensing valve inoperative and ABS not fitted or inoperative (1.1.17 (c) (ii))

Repair immediately (major defects):
Bonnet primary retaining device ineffective (3.1 (c))
Offside Front Suspension component mounting prescribed area excessively corroded significantly reducing structural strength jacking point area (5.3.6 (a) (i))

Repair as soon as possible (minor defects):
Offside Windscreen damaged but not adversely affecting driver's view (3.2 (a) (i))

Monitor and repair if necessary (advisories):
Steering wheel very close to column switches
Brake pipe corroded, covered in grease or other material front to rear (1.1.11 (c))
Nearside Rear Wheel bearing has slight play (5.1.3 (a) (i))
Offside Rear Wheel bearing has slight play (5.1.3 (a) (i))
Nearside Rear Road wheel slightly distorted (5.2.2 (c) (i))
Offside Rear Road wheel slightly distorted (5.2.2 (c) (i))
Park brake effort on minimum percentage to pass
Rear service brake effort low

So starting from the top of the list, the tie rods and rear bearings were simply where I'd not tightened the locking nuts properly and instead of the garage just tightening them (literally a few minutes work) they just failed it. The top mount being broken is a bit off as I had the suspension off the front as you can see but when I inspected it I didn't see a split but I haven't yet removed it again to look. The more pressing issues are the brake regulator for the rear brakes and the front jacking point. I did have trouble bleeding the rear brakes so that one makes sense and I knew about the jacking point but didn't think it would fail but lesson learned.

The wheels are another issue that I've already addressed:

(https://farm2.staticflickr.com/1769/43053934552_81d206ba4a.jpg) (https://flic.kr/p/28AwELq)

Bought them off eBay, the story goes that they were removed from the car by the dealer at purchase and been stored ever since. They're genuine G60 steels in a 15x6J size with an ET45 which is 10mm more than the Sebring wheels I currently run which is nice. Plus the tyres will swap straight over so it's a cost-effective way to carry on the G60-theme that seems to be running through the car now. The MOT guy did say to me the wheels were probably OK but the fact the tyre shop advised fitting them to the rear and now they've been picked up under the safety inspection they have to go.


The windscreen needed replacing when I bought the car so that's no surprise and the brake lines were also needed to be done. Just a lesson that skipping jobs to speed things up doesn't work...


And now the elephant in the room. The jacking point. It's not something I can resolve myself, especially when it looks like this:


(https://farm1.staticflickr.com/916/43053934272_51f0e7a407.jpg) (https://flic.kr/p/28AwEFA)

Luckily for me, there are some body shops/painters just 10 minutes drive down the road so I popped into them for a chat, turns out there an awesome bunch of guys:

https://en-gb.facebook.com/leadfoot.racing.lfr/

Check out the crazy TDI Corrado they've just finished, the thing is insanely awesome in the metal. Keep an eye out for it when touring around at shows. We discussed options and came to a plan to cut away the jacking points, plate them with fresh metal and use box steel from the sill to the chassis leg to create a much strong, reinforced jacking point. This will allow me to safely get the car up in the air without worrying about damaging the floor which is essential as this project will require a lot more work yet. There will definitely be much more work from these guys being done, just right now time and money (as always) don't allow for the full-scale crazy plans.


To end this update, here's how she currently stands with a new grill:

(https://farm2.staticflickr.com/1809/43104087481_f04eb78fcf.jpg) (https://flic.kr/p/28EXHu6)

Oh wait, one more thing...

(https://farm1.staticflickr.com/925/43104111041_db1c1ded52.jpg) (https://flic.kr/p/28EXQui)

Yes, that's Harriet, the other car that appears to have dropped off the radar. Well, the old 1.6 engine is out and sat waiting to be scrapped (unless someone wants to come to grab it for free) and I've fitted the Corrado VR6 front cross member. Got to source a VR6 subframe and gearbox, going to opt for a 5 speed for the short term just to get the car driving and functional. It means parts are easily available off the shelf and cheap enough I can get it together sooner than trying to get the 6 speed working. I'm trying to get back to her once a month at least now to get things moving again.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 08 July 2018, 13:08
Bagged myself a G60 rocker cover to brighten up the engine bay:

(https://farm1.staticflickr.com/920/43202541552_d6a9366ea7.jpg) (https://flic.kr/p/28PEjs5)

And a genuine Momo steering boss to move the wheel away from the stalks to clear the MOT advisory off:

(https://farm2.staticflickr.com/1787/29381210058_d0ebae6e26.jpg) (https://flic.kr/p/LLjo8d)

Got a selection of tools to help finish off the remaining MOT jobs, got a Sealey suspension nut tool:

(https://farm2.staticflickr.com/1823/43202538142_11fd57c323.jpg) (https://flic.kr/p/28PEirh)

Had to file it down as the lugs were too big for the nuts, but it does make the job a lot easier none the less. Also got all my brake pipe tools:

(https://farm1.staticflickr.com/835/29381209798_aa6c113dd0.jpg) (https://flic.kr/p/LLjo3J)

Had Friday afternoon off work so decided to get out in the sun and crack on.

(https://farm1.staticflickr.com/837/43202540162_45c9a25747.jpg) (https://flic.kr/p/28PEj37)

Driver's side suspension. Looked alright, top mounts have in fact been replaced within recent years as they were Febi items which didn't show any real signs of wear. However, the dampers are definitely worn as the second picture shows:

(https://farm1.staticflickr.com/923/29381209118_3dabdc2256.jpg) (https://flic.kr/p/LLjnR1)
(https://farm1.staticflickr.com/841/29381208958_1ba2a0aeff.jpg) (https://flic.kr/p/LLjnNf)

No rebound left in it! No leaks from the gas/oil in the main body so they'll do for now until I can afford a complete overhaul of the system. Got the other side off and the top mount was also fine, the MOT garage had failed me on this:

(https://farm1.staticflickr.com/837/29381208748_af76c7d709.jpg) (https://flic.kr/p/LLjnJC)

Wasn't sure a dust cover is a pass/fail item, but apparently so:

https://assets.publishing.service.gov.uk/government/uploads/system/uploads/attachment_data/file/671818/mot-inspection-manual-for-classes-3-4-5-and-7-from-20-may-2018-draft.pdf

A handy one to have so you can check out what your codes really mean as the description on my sheet would lead you to believe the top mount itself has failed, so double check first before rushing out to buy replacement parts. Next step now really is to get the brake lines and rear compensator sorted, into the body shop for repairs and then back in for an MOT.

Planning to completely overhaul the suspension now with new dampers, springs and hardware which includes bolts. Freshen everything up then get it fully aligned and the caber corrected as much as possible before putting her into daily service so I can crack on with the 6R.
Title: Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
Post by: th3_f15t on 15 July 2018, 11:13
Decided to get the new boss kit installed, you can see the difference in height:

(https://farm1.staticflickr.com/918/28550013757_b8eb079137.jpg) (https://flic.kr/p/KuShqv)
(https://farm1.staticflickr.com/920/29549288768_efdfee5bbf.jpg) (https://flic.kr/p/M2aQ51)

Feels a lot better behind the wheel now. Got to sorting the brake lines out and fitting the new regulator for the rear brakes as well:

(https://farm2.staticflickr.com/1801/28550013287_8eb3254b8c.jpg) (https://flic.kr/p/KuShhp)
(https://farm1.staticflickr.com/842/29549287958_928c6e57a2.jpg) (https://flic.kr/p/M2aPQ3)
(https://farm1.staticflickr.com/834/28550012637_1f9103fb4b.jpg) (https://flic.kr/p/KuSh6c)
(https://farm1.staticflickr.com/920/28550012327_70caea02a4.jpg) (https://flic.kr/p/KuSgZR)
(https://farm2.staticflickr.com/1829/29549289348_d6c5837c67.jpg) (https://flic.kr/p/M2aQf1)

Haven't seen flares that good since my dad showed me a picture from his teens. Would have bled the brakes through but I've not got any tube to do it so I'm off to Halfords to get some supplies.