91' Mk2 GTi 16v Restoration project by newbie – help request

[francescop1]

So like many before me, my first car was an mk2 gti, but not just any mk2 gti – a (formely) mint, one-owner 50k mile, completely unmolested 91’ valver in alpine white.

Note: I cannot provide any pictures right now as I am in a different country to the car.

So that was about five years ago. Now the car has about 90k and is tucked away in a garage after being neglected for the last couple of years while im trying to get the funds together for a complete restoration. I am aiming for something around the 3-3.5k mark for the total cost and I want the car to remain as original as possible. The project will probably commence during next summer when I have more free time on my hands. I wanted to use this thread as an opportunity to bank on the know how of more experienced people in these forums. I have done some preliminary research and I am posting my findings for to get some feedback along with getting some specific questions I want to have answered.
-the car will not be doing any track work.
Engine:
I am aiming to do a complete DIY rebuilt of the engine to save money and get myself better acquainted with my pride and joy.
Most of the information I have on this comes from the Haynes mk2 manual and this excellent channel on youtube that details a rebuilt in 54 parts that I have put into a playlist.

http://www.youtube.com/view_play_list?p=C39A55371D924CB8

The video is pretty comprehensive but I would like to do a more thorough job with the cylinder head and block.
These are a couple of resources I have found for this.

Block:

http://www.pirate4x4.com/tech/billavista/PDFs/Engine%20Block%20prep%20by%20Standard%20Abrasives.pdf

head:

http://65corvette.nonethewiser.net/technical/diyport.pdf
http://uk-mkivs.net/forums/p/362936/2467156.aspx
http://www.clubgti.com/forum/showthread.php?t=38090
http://www.eastcoastdubs.co.uk/forums/viewtopic.php?f=22&p=40997
http://portandpolish.blogspot.com/

Equipment:

http://www.frost.co.uk/

My question on this is, these guides detail how to give the head a smooth finish everywhere, but I have read elsewhere that in certain parts it is best to give it a rough finish which aids fuel mixing. Is this accurate? Can anyone provide any instructions for this?

During the rebuilt I will be using OEM parts apart from the parts listed below. Please let me know if you think some of these parts will not be a worthwhile upgrade or if there are other parts that I should aim to upgrade from OEM.

Engine & Transmission:

ecotec valve
ecotec valve filter
pipecross induction kit
k & N filter
neuspeed sport camshaft  (this is for the inlet cam. Description says neuspeed recommend only changing the inlet cam.)
vibratechnics front engine mount
vibratechnics rear engine mount
vibratechnics gearbox  mount
jetex resonated exhaust
Neuspeed Shift Repair Kit Golf 2
Neuspeed Short Shift Kit Golf 2
Neuspeed Solid Shifter Golf 2
ecu superchip
tsr buffled sump and windage tray
Tsr 4 layer steel Head Gasket
kent cams competition cambelt
ecs magnetic drain plug
arp resusasble bolts

Brakes:

goodridge hose kit (I haven’t quite grasped how many hoses I would need for my car with a standard brake setup)
Brake discs front g60 280mm (is this worthwhile or should I stick with OEM or aftermarket 256mm?)
pagid fast road pads front
pagid fast road pads back
calipers for 280mm conversion (G60 OEM?)

From what I have gathered, I would only need G60 calipers and discs to go 280mm at the front. Is this corrent?

Suspension:

powerflex bushes (Im aiming to upgrade with everything they offer
Bilstein Streetline Kit Mk2 Golf (can you recommend anything else at this price point? Would it be better to go for a similarly priced coilover kit?)
front upper strut brace
front lower strut brace
rear strut brace (are the front lower and rear strut brace worthwhile?)



Below are parts that I am aiming to replace but with new OEM parts. Please let me know if you think this is worthwhile or if should just refurbish them. I have looked at uprated aftermarket versions of these parts (pistons, conrods, rings etc) but they are prohibitively expensive on my budget. If anyone can direct me to some middle ground solution on any of the parts below that would be ideal.
Engine & transmission:

cylinder block:

main bearings
crank
crank bolts
pistons
piston rings
conrods
conrod bolts
intermidiate shaft
oil pump
engine sump

cylinder head:

valves
valve springs
hydraulic tappets
exhaust camshaft
spark plugs

Suspension:

cv joint kit
cv joint liner
Bearings

Wheels & Tyres

michelin pilot exalto 195/50 R15 (Anyone have any experience with these? Any alternatives? Is this the correct size for OEM BBS RZ?

And finally I am after a set of BBS center caps http://www.justmatz.co.uk/proddetail.php?prod=OriginalBBSRS
These are the only ones I found, but they are a bit steep at 200 quid.


- Edit as im quite tall, 6'5" I would like to sit as low as possible. I have the standard height adjustable driver's seat that is not low enough and I know that the lowest you can go is by fitting corrado front seats that go right in. I havent been able to find any information on whether there are different versions of these (apart from the trim). Are they all recaros?
 
Will these mounts make them lower? 

http://cgi.ebay.co.uk/HC-738-OMP-SEAT-MOUNT-BRACKETS-VW-GOLF-MK2-GTi-16V-G60-/350346452893?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item5192469f9d#ht_7482wt_1141


Thank you for your time,

Michael.

[Wayne]

A few small points these 2 items are a complete waste of money ecotec valve & ecotec valve filter.

Superchip I would go for a remap when it is all in and sorted.

I see no point in changing the crank, pistons, conrods, intermidiate shaft or valves unless you have bore wear in which case go for a slight overbore with new pistons.

[rich1977]

Didn't think the k jet valver could be mapped

[Wayne]

Didn't think the k jet valver could be mapped

Good point, I think your right.

[francescop1]

http://superchips.co.uk/search?make=38&fueltype=1&model=239&variant=1541

This is what led me to believe that it can be done. Are all 16v mk2s kjet? It does look kind of suspicious as from what i know only the fuel mixture settings can be modified on a kjet...

[rubjonny]

depends what the superchip they are offering does, 16v only got electronic ignition so thats the only bit that can be 'chipped'.
You could get a k-star+fuel kit back in the day which allow you to change the ignition and fuelling. As well as a box to play with ignition it also had a fuel injector type thing inline with the wur to allow you to tweak the fueling, i wasnt aware of any other tuning kit that does the same thing though? 
maybe the superchip package is a tweak of ignition map plus then wur mod to increase the fuelling a little?

with the seats you either fit scirocco or corrado fronts to make em sit lower, or go aftermarket. those omp mounts wont do anything to the standard seats they're for aftermarket buckets.  if you swap your front seats for pre-90 mk2 ones, you can change the driver side metal base frame for a MK3 Polo GT/G40 one which will make it sit lower but keep oem seats. Has to be a height adjust base the fixed ones have the legs at the wrong angle, can bend but bit of a bodge.  You can get scirocco seats in mk2 patterns as well but quite hard to find.  all depends on if you want to keep it looking original!

[Wayne]

http://superchips.co.uk/search?make=38&fueltype=1&model=239&variant=1541

This is what led me to believe that it can be done. Are all 16v mk2s kjet? It does look kind of suspicious as from what i know only the fuel mixture settings can be modified on a kjet...

Lol at the 8bhp extra claimed 

[Sam]

Good luck in finding a K-Star unit, nevermind somone who can actually plug the damn thing in and map it. Right pain in the arse for me

[francescop1]

so how come the 16v uses kjet when the more "advanced" digifant injection was used on the 8v?

-the ideal thing for me would be to fit a megasquirt and work on it as part of my final year project in school, but im not sure if thats gonna fly with my school :/

[Neo Badness]

so how come the 16v uses kjet when the more "advanced" digifant injection was used on the 8v?

-the ideal thing for me would be to fit a megasquirt and work on it as part of my final year project in school, but im not sure if thats gonna fly with my school :/

K-jet is rubbish imo, as has been outlined in previous threads. Megasquirt isn't exactly OEM though is it? In which case you could always put ITBs on there or swap for an ABF or something. Depends how much of a slave you are to the OEM?