Author Topic: 20vt mk2 sleeper project.written off :(  (Read 149234 times)

Offline lemski

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Re: 20vt sleeper project from page 52
« Reply #560 on: 02 July 2012, 18:47 »
What the sprinter ones, my mates is alright on his.

Offline lewis1641

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Re: 20vt sleeper project from page 52
« Reply #561 on: 02 July 2012, 22:03 »
It is indeed a splinter intercooler, bought because it was 40 quid and included a load of pipework. If it causes lag that can't be mapped out then it can be binned and replaced.

Have not had time to get the front end back ok to see how it is going to sit yet though.

Offline lewis1641

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Re: 20vt sleeper project from page 52
« Reply #562 on: 20 October 2012, 10:23 »
long overdue update on this,

got the mounts sorted in the end, my mate was getting one lined up then bolting it down fully then trying to line the others up, loosened the first off and they all lined up nicely.

so engine and box are in, next job, driveshaft.

the o2a box has 100mm flanges so the standard shafts bolt straight up.  This is ok if you are sticking with mk2 based hubs and brakes but we opted for mk3 bits, more of which later.

The shafts i am using are mk3 gti items. This gives a 100mm flange, thicker splines for the hub and the correct length for the widetrack conversion.

Offline lewis1641

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Re: 20vt sleeper project from page 52
« Reply #563 on: 20 October 2012, 10:23 »
Hubs/Brakes

Initially i was going to run a 312mm set up (that was fitted to the wife's tdi estate), however this limits my wheel choice and having spoken to a few people on the subject, they would be far bigger than necessary.

With this in mind i have gone for a 288mm set up off a vr6 (thanks to gary forrest)

5 stud mk3's have a different ball joint set up to 4 stud cars (incl mk2) so you cant bolt the hubs onto the bottom arms.  Thankfully the arms are interchangeable though.

The arms that came off the mk2 were polly bushed and we managed to press these out and into the mk3 arms.  With the arms bolted in place the hub can be bolted to it.  From here you have options.  To keep it 4 stud the centre part of the hub can be pressed out, new bearings in then use the centre from your original hubs. you'll then need to source 4 stud 288mm discs though.  I was happy to run 5 stud though so fitted up the hubs as per stock.  Doing this also gives you 14mm wheel bolts.

Mk3 vr6 flexi hoses are then needed to plumb the calipers in.

The next issue is the steering arms. mk2 and 3 track rod ends are the same part number so are interchangeable but the rack ends are longer in the mk2 so these need swapping over too, otherwise the wheels will be pointing in opposite directions.

edit, mk 2 and 3 struts are interchangeable too so they bolt up to the hubs as normal.

further edit, rear brakes.
To match the front end it would be normal to install a mk3 rear axle, this will give a wider track and a 5 stud brake set up.

I have cheated and just fitted mk3 gti rear discs (wheel bearing part numbers are the same so they are a direct fit).  The wheels i am using are 8.5" on the rear so i need all the room i can get, hence sticking with narrow track, for now at least.

Offline lewis1641

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Re: 20vt sleeper project from page 52
« Reply #564 on: 20 October 2012, 10:25 »
Intercooler/Exhaust/Radiator

I struck it lucky on ebay and found someone breaking a mk2 with an AUQ lump fitted. I secured the custom exhaust, intercooler and pipework for around £100

The exhaust is a bodge and will be replaced as soon as funds allow. It works and fits so is ok for now.  The "custom" downpope is nothing more than the standard pipe hacked about, the system is 3" wuth a single silencer and a god awful back box.  When i get my own way i want the back box to appear as stock as possible


IMAG1524 by lewis1641, on Flickr

Intercooler is off a mercedes sprinter and is pretty big.  We chopped the slam panel about to enable it to fit. we have got just enough room for the 4 light grill to fit. Just


IMAG1523 by lewis1641, on Flickr

The internet says you need a 1.3 rad for the conversion, otherwise you need to mess around with custom cooland hoses/search around scrap yards.  I ordered a 1.3 rad.  Turns out there are several of them! I now have the right one and i will add part numbers.

Offline lewis1641

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Re: 20vt sleeper project from page 52
« Reply #565 on: 20 October 2012, 10:43 »
so the current situation is the car is sat in the unit, 80% done.

had a few issues with the wiring. did everything on rub jonny's guide (plus plenty of emails - massive massive thanks for the support) but still had issues. It seems the ignition switch is faulty so waiting for delivery of that from ecp this morning.

Also had an amusing issue with the brake lights, connected the battery and the brake lights are on continually. Lots of head scratching and panicking that we had spliced a wrong wire, turns out the switch in the pedal was faulty!

so to do,

1. replace ignition switch which will hopefully allow the engine to start
2. woop and high 5 everyone on the industrial estate
3. weld captive nut back on chassis leg
4. front brake flexis
5. radiator hoses
6. relocate battery or intercooler
7. GEAR BOX BOLTS
8. clutch cable (off a 1.3 mk2
9. wheels and tyres
10. check fluids and a full bolt check
11. mot
12. start the bodywork.....

Offline lewis1641

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Re: 20vt sleeper project from page 52
« Reply #566 on: 23 October 2012, 13:26 »
we have life!

gareth from map-tech.co.uk worked a little magic last night. we have an issue with the fuel pump wiring but we got the engine struck up

massive relief that it runs!

slight concern that there was rather a lot of oil coming out of the turbo-intercooler hose though...

Offline Dave_IOW

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Re: 20vt sleeper project. ITS ALIVE!!!
« Reply #567 on: 23 October 2012, 19:28 »
Good times bud, bet your buzzing  :smiley:

Can't wait for the first signs of life from mine!
Project: Mk2 20vT trackslag
Daily: Mk2 GTI typ19

Offline lewis1641

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Re: 20vt sleeper project. ITS ALIVE!!!
« Reply #568 on: 29 October 2012, 09:57 »
massively relieved although a little concerned at the oil coming out the turbo lol

The workshop is looking really rough at the minute so we had a clear up and fitted the wheels to make the car look a little tidier.

hope you approve...



IMAG2097 by lewis1641, on Flickr


IMAG2098 by lewis1641, on Flickr

apologies for the low light pics

got a few other jobs looked at too, nothing exciting but connected the vacuum pipe for the brake servo, used one off a 1.9d mk3 but that wasn't really necessary, just made it a bit easier and tidier.

Installed the 1.3 golf clutch cable which seems to actually do something

Relocated the battery slightly, its still on the battery tray but running front to back and tucked right under the slam panel.  This has negated the need to put a tight s bend in the intercooler pipework. Looks a lot neater too.

Offered up the vr6 shifter assembly only to find its been hacked with so not wide enough to fit. Going to have to cut and shut the base off the mk2 one

Offline Cory

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Re: 20vt sleeper project. ITS ALIVE!!!
« Reply #569 on: 10 December 2012, 23:54 »
hey man.

would you mind posting a picture of your battery solution as i think i have the same idea in mine, but was thinking that id have to move and reweld the battery tray a little. also what fuel pump you using, how did you wire it up and what issues did you have?

hoping to get mine started up tomorrow and the fuel pump is my only concern at the moment.

thanks in advance
Cory