mk1 golf 1.1c, now with added ALT 2.0 20v on 48's!

Hi chaps, not sure who will remember me or the car but here goes,

in the begining there was a chap called andy, he built a lovely example of a mars red golf, found in a build thread here, 7 years ago - http://www.clubgti.com/showthread.php?81688-Mk1-82-Golf-buildup-thread-extra-100bhp!&highlight=

not that any pictures are still in his photobucket, so i'll start from when i got it.

bought it 18 months ago as a 1.8 16v on KJET,

after months or misfires and pinking i decided to put it on carbs, a nice easy route, at the same time the dyno i entrusted to set it up dropped a self tapper down the bores, so out that came and over we went to a 9a



(trumpets made using the guide on here, thanks)

made good power, 160 at the wheels



had a good few months of lovely driving out of it, every day use, clocked up 22,000 miles in it in over the 12 months without skipping a beat, took it to ultimate dubs and come back with best wheels in april.....



then 2 days later, the mix of cold R888's and an inexperienced corsa owner got the better of me and this happened



not one to be too downhearted on the whole situation (might've been something with buying an RS4 to daily as an alternative) but i figured it was time to make the car how i wanted it, so i set to work trying to figure out the best engine i could opt for, considering light and good NA power were the key.

plenty of research on here found that there was a decent sized alloy blocked engine from a 2005ish A4 that should do the trick, the 2.0 20v ALT, so i got searching and found that they've come down in price pretty well and were easily available, off to kent i went in the parts hauler...



and here it begins



old vs new -



and the car looking pretty sorry for itself!



next steps are to fab up the front engine mount as it doesn't appear to be anything like either the 16v or 20v bolt positions, shouldn't be too difficult as there will be loads of unused holes i can borrow, and need to work out the water pump/alternator configuration as it's quite a cumbersome old beast sat on the front, i'm sure it'll look a bit clearer when i've mocked it up

planned spec is -

keep the coil on plugs
emerald K6 (sort of already bought)
big throttle bodies, maybe a 45
design the exhaust manifold

maybe bring bottom end up to spec, I'm a crankshaft design engineer for ford so i'd like to have a bash at seeing how strong i can make it and bring that engine speed up a few thousand

thanks for looking

 

the intake for these engines is essentially PERFECT for throttle bodies/carbs if you space the bodies accordingly, it's almost tempting to use it but the ID is only 38mm, i'm after something a little larger so i'll have to dust off the welder



this is the front pulley/mount arrangement for those interested -



reading back through that i've noticed there's not a single picture of the car in its entirety, so here you go -

 

Very nice

 

I will be keeping a close eye on your build. MK1 looks fab

 

new engine in, sort of, lined it up



the gap between the 2 sides of the engine mount is 65mm, which is the same as a mk2 escort leaf spring bush, which i'll use inside some old rollcage tubing as they both have an inside diameter of 47mm.

also need to get a 16v cambelt tensioner as the hydraulic one currently on the engine sits where i want to put the new mount

 

Time to make an engine mount -



into CAD, then cut with the plotter -



couple of more steps, added some tubing -



finished -



Engine in



onto getting the westy front end finished next -



got this far before the welder packed in halting play for yesterday, today and probably next weekend



got a few other non-welding bits to mess with, braking system, gear linkage (sticking with the O2O so got some plans for the linkage)

 

What bush is that you used on the drivers side engine mount!?

 

mk2 escort leaf spring bush

 

Cheers.
Was looking for a smaller bush than the vw ones to make mounts for my 20v mk1 project

 

Those wheels! What are they?

 

HTN Rennsport, magnesium centres, with 195/50 R888's

 

Do the ABF/KR heads fit onto the ALT block? Loving the work so far , and the rims!

 

unsure, i'd imagine you have the opposite problem you usually get when putting a 20v head on a 16v bottom end (certain waterways need blocking up)

funny you should all like the wheels so much, this is what happened to them in the crash.....



that's work hardened 30 year old magnesium for you

got myself a little souvenier of the occasion out of it though!

 

Shame about them alloy wheels. Anyway quick answer to your question..3 holes at rear of block can be plugged or you can use a 8 valve 2.0 crossflow head gasket. You will need 10mm 12.9 tensile bolts to secure head to block.

 

I've got this surplus to requirements now if you want a straight bolt on inlet..




Good luck with the project.. Wish I still had my ALT mk1 now!

 

That's a 20v mani?

 

looks like one....

thanks but i'm keen on fabricating up something special for it, intake and exhaust, done a few intakes in the past (my MX5 was on throttle bodies & the mk2 escort in my signature i made the inlet for that too)

got both the intake and exhaust flanges being made up at the water cutters as we speak.....

 

watching this closely mate, even if you don't reply to PM's

 

which forum? not received anything!

 

Moved the car to it's new location to hopefully move things along a bit quicker



Started working on the rod change linkage, not going to go over to cable on the basis that rod change should be acceptable with the torque the engine is putting out and i saw the potential to make the linkage pinpoint accurate

started off by replicating the OEM rods with rosejoint and stainless bar


next was to remake the nylon bushes in aluminium



fitted to the linkage -



after the picture was taken i fitted the misalignment washers and cut down the bolts to the correct size, the linkage is now a LOT more accurate, still need to work on the shifter itself before i'm happy with it though



and looking back at some old pictures when it was on 16's got me searching for some RS's, as luck would have it there was a gorgeous set in the classifieds at a price i couldn't resist



it's going to be a shame to split them but they'll need new barrels, colour, PCD and offset change if i want them on the mk1

next on the list was fabricate a front engine mount, unsure as to what would fit i figured it'd be easier just to make my own! so i ordered some tube and got to work







using a mk2 escort leaf spring bush, was a bit too big for the metal i could find so i attempted turning it down to the correct size



turned out you can turn poyeurathene too

made a bracket for the front panel side and fitted it to the car



engine bay starting to come together!



headlights came too, next task is to get them fitted, they don't have any mounting bolts or holes haha, think i've worked out how though





hopefully starting on the exhaust manifold soon! got to brush up on my CFD first!