VW Mk2 Golf, AWD big turbo build

[savagesam117]

So, I thought I’d make a thread, because why not!? Although, it’ll be a shortened version.

It’s a 3 door Mk2 GTi 16v at heart, but I’m going to convert it to AWD and strap a larger than normal turbo to a 1.8t as a temporary solution whilst I build a 16vT with an even bigger turbo so it’ll eventually push 500+ little ponies.

The shell is solid, couple of small bits of rust as to be expected. It’s an old golf.

I started at the end of Feb. So I got it up on the rotisserie,

cleaned the underside,



checked for any more rust, mmm no rust!





Then I got the grinder out. I’m a tight git and didn’t want to pay for parts from a 5 door “Syncro” so I made it all. Boot floor cut out for diff clearance



With the diff mounted I could see the tunnel needed to be raised as I wouldn’t have space for a nice big exhaust.

 

[savagesam117]

Then choppy choppy of the tunnel.



I was going to fit the Syncro stuff then upgrade to halves so I started fitting that.



Mocked up to the height I wanted and then started to fabricate it in.



Almost finished.



This is my new boot floor support.



then got a bit bored of that, so I replaced the battery tray because it had been poorly repaired.



and then welded a new panel in.

 

[savagesam117]

ill be interested to know the big turbo setup you choose for the 20v, im in the same boat here with a forged engine but standard k04 at the moment.

I’ve got a Garrett GT2870r or something, but I don’t think I’ll use it. But I don’t know, we’ll see! if I had a K04, which I do in the shed, I’d go for one of them AET380’s. 380+ bhp. Happy days!

 

[savagesam117]

Lovely, not enough angle grinder and welder action on this forum these days.

There’s plenty of grinder & welder action here! I’ll try and update a bit more later on

 

[savagesam117]

Nice, how much extra weight will AWD add? Adding AWD and possibly DSG to old cars somewhat intrigues me.

also will engine internals need strengthening?

All in about 75kg. Takes it to about 1050kg from 975 to something. I’m tempted by DSG unsure if I’ll make the jump yet. Maybe when the other engine gets fitted.

the 1.8t will have a set of rods and a refresh.

 

[savagesam117]

So I was away on site and was bored one evening so I bought the running gear off a Mk1 TT.



threw it all in the boot of my car and drove it 120 miles to my dads.



Got the car on it’s wheels



And whilst I was there I thought instead of adapting the subframe to fit, I’ll make it chassis mounted like the TT. So I reinforced the chassis leg and went to town. And repaired the poorly repaired hole in the turret.





I then put the engine back in on its new mounts and mocked up the dog bone.



Tadaaa, need to tidy it up but I’ll do all that before powder coating.



I then set out on making the haldex bracket now I had the engine and prop in place.



Front support



and she’s in!

 

[savagesam117]

Ooooh... a rival for Binky.

Care to elaborate please?

 

[savagesam117]

You don't know about Project Binky? It's one of the best things on the Internet. Been going for 7 years and the end is almost within sight...

Take one vintage Mini. Remove all the rust. Remove running gear.
Take one Celica GT4. Remove running gear.
Insert into Mini without making the Mini not look like a Mini.

Full playlist.

https://www.youtube.com/playlist?list=PLGSOZAHg1yQEatqhWza_ae83e313-GLTO

Definitely not a rival, he’s got a workshop and everything! I’ve just got a driveway and a garage full of tools. And it’s just myself and my dad.

It’s really annoying to watch?

 

[savagesam117]

More the cars a rival. Also the tools they use most are the grinders(s), welder, cardboard and kettle.

Although the jig Nick made for the Mini is pretty damn cool.

The early episodes are a bit ropey but they get into the swing of it pretty sharpish.

Maybe I’ll skip a few and get to the fun stuff.

Well I’ve got those tools, and then some. No CNC machine though

Yeah, he’s gone a bit more hardcore than me. They did make AWD golfs so I’m merely recreating it, in a 3 door shell because they only made 75 of them.

 

[savagesam117]

can you expand on this a little, please?

They made a Syncro Mk2 Golf, but they were pretty much all 5 door cars. They made a very limited run of the 3 Door 16vG60 Syncro, about 75 of them. And they’re rare as rocking horse ****. I don’t like 5 door Golfs, so I figured I’d build a 3 door version.

 

[savagesam117]

I had a Rallye Golf, they were all three door and they built 5000 of them.

And what about the Golf Country - did they not do a three door?

Yeah, but that’s like a hideous version of a normal Golf IMO.

As far as I’m aware, they only made the country a 5 door

 

[savagesam117]

They were the best looking and I’ve had all quite a few of the others! But it’s still not a 4x4 Mk2 though?!

It’s not True 4x4 no, but with controlable Haldex, it’s good enough for me.

 

[savagesam117]

Sorry, slightly tongue in cheek comment really about the Rallye Golf not being 4x4 when I really should have said AWD. An AWD mk2 whilst not common as muck is not mega rare either, but good on you for your project. I used to be very active on the Mk2 scene years ago and a lot of friends were running 4x4 20VT/VR6 with big power. Anyway, nice to revisit it and hope your project goes well.

No I know, I’m not doing it for anyone else. I’m doing it because I want one, not bothered about rarity, value or anything. I just want to enjoy it and it’s always been a car I’ve wanted to build, so why not?

Once this is finished, it’s on the hunt for a Mk2 Escort so I can do a bonkers rally car

 

[savagesam117]

Am curious about the spec of the 16vt you are going for, I was looking to ditch mine and go 20vt so the reverse of what you have going on. I wish I had the skills to go awd for mine though as it would never get traction as it is.

To be honest, I haven’t got a clue. Not looked that far ahead. I’ll have a look into it when the car is built. I do have an ABF stashed from a Mk3 GTi I was given though.

 

[savagesam117]

Paging @NigeP

Loving this build mate, keep the updates coming!

Haha, the pinderwagen is one hell of a car, and he can certainly drive! I couldn’t even remotely keep up with him. He just kept coming past me! And I didn’t get a chance for a ride, maybe next time.

Things have stalled at the moment sadly. Hoping to make some decent progress before Christmas.

 

[savagesam117]

Is this for the road? Just wondering if you've considered the fact it'll need an IVA test, or if you're just going to chance your arm?

I only ask just in case it's something that's not popped up on the radar, because I've seen a few people fall foul of it in recent history.

All doable, mind, as it's just a list of requirements – but it obviously ups the budget a bit and entails a Q plate.

I’ve spoken to a few people about this, and they say it won’t need one. Maybe I’ll contact them directly and see what they say. Either way, it doesn’t really make much of a difference. It’s going to cost an arm and a leg anyways.

 

[savagesam117]

Managed to get a bit done today.

I got my boot floor welded in. I’ll apply sealer tomorrow



Then thought I’d have a go at driveshafts well the lengths at least, I’ve been putting this off for a while now.

Ones pictures are the Mk2 Syncro rear shafts, haldex is bigger.



One obligatory cat picture with some chopped up shafts.



After lots of faffing with wheel movements etc to get full articulation, we have one side!



Then repeat this process and we get another one.



Seeing as I am getting fed up with these sitting in my dining room, I thought I’d give or throw the roller wheels away and just leave these on for now.

 

[savagesam117]

To be fair, I've been trying to build a spaceframe Exocet from an MX5 for a while, the most awkward bits of an IVA are not likely to be an issue if you're using standardish external bodywork and OEM (non engine) electrics and lights.

External will be as it left the factory in 1986 right down to the factory 14” bottle top wheels. And everything inside is stock, apart from the engine loom.

 

[savagesam117]

Upgraded the driveshafts from 3 tack welds to some 3mm pipe. So they won’t get damaged getting thrown around as I take them on & off testing and faffing.



Then went to meet Tin Worm.

Other than the sill which I’ve repaired, this is the last of it.



cleaned back to see the full extent.



Started cutting.





I also made myself a battery holder at work yesterday.





tadaa, not sure where I’m going to put it yet though.

 

[savagesam117]

Finished up the arch repair,



Then moved my shifter slightly, all fits fine.



And finished up the inside of the boot,



Made up some angle and tacked it in.



And fits nicely.