Built In A Barn: 4motion 450bhp Mk2 GTI With a few of my close friends telling me I should put some sort of build thread together for my little project here goes! What started off as simply having my Mk4 GTI remapped and a few little bits here and there quickly lead to the following. After deciding Id quickly get bored of the 220 ish horse power on offer from the simple remap I decided to look at moving to a big turbo conversion. This would have meant replacing at least the conrods to cope with the additional power that would be available. One thing lead to another and the motor quickly ended up being more than just rods. The intention was to always drop the motor into my FWD Mk4 but I have always wanted a MK2 for as long as Ive been into cars. A new job earlier in the year has/will hopefully give me the funds and time to now build what I have always wanted! With the sort of power Im looking at I started to look at a 4 wheel drive conversion. Synco parts are now going for crazy money and my fear of breaking a syncro part and the car being off the road for months whilst I located a replacement drive shaft in the UK for example didnt sound that appealing. My only feasible option was to look at using the 4motion/Quattro running gear from the TT/S3/R32 etc. I will try and update this as often as I can, if anyones on Instagram or Facebook just search @sa_engineering or https://www.facebook.com/seanallenengineering So this is where Im up to! Chassis: (Working on) 1989 Small Bumper mk2 Golf GTi Audi TT mk1 Quattro Subframes And Associated Parts Audi TT 312mm Front Brakes (For now) Audi TT Rear Brakes (For now) Suspension (TBC) Wheels (TBC) Engine Spec: Now Complete (Estimated 430-450hp) 1.8T Block Bored To 82mm (1825cc) AGU Crank And Pegged Pulley Integrated Engineering 20mm Rifle Drilled Conrods Wossner Forged Pistons 1mm Oversize AGU Big Port Head, Ported SuperTech Single Collet Valves, Springs, Titanium Retainers. Piper Cams All New OEM Oil Pump, Water Pump, Tensioners, Cam Chain, Etc Integrated Engineering Manual Cambelt Tensioner Gates Kevlar Cam Belt 02M Gearbox GTX3071 .63 Tial Hotside (Owen Developments Built) Part 1: From the beginning I located a crash damaged 20v Audi A3 for less than 200. The engine was removed, the rest sold on/scrapped. The car had done just over 145k before it had a car slide into it in the snow a couple of years ago. The owner began to strip off the bent and broken parts with the intention of repairing it himself. He quickly lost interest and it found its way into my hands for effectively scrap value. I quickly set to work with a friend of mine pulling the motor apart. It was in fantastic condition considering the mileage on it. It didnt really matter what we found as 95% of it was going to be replaced. Bare Block: The head was the main deciding factor as it was the large port AGU version, ideal for what I wanted to build. Head Fully Stripped: Part 2: Rebuilding Bottom End With the block back from being re-bored to 82mm I spent a few hours cleaning up what was left of the old paint and surface rust prior to painting. A nice delivery of parts showed up at work Rings being gapped and measured Ready for new mains Bearing clearances being checked Crank end float checked Ready to go in Block painted And in they go Part 3: Bottom Pulley Peg With the upgrade valve train going in and the horror stories Ive seen and heard of the keyway shearing off I decided to peg the bottom pulley to the crank with 2nr 3mm high tensile steel dowels. 2.9mm drill bit, 3mm reamer and dowels Preparing the pulley Dowels into crank Finished up with the new OEM stretch bolt Pulley and new OEM oil pump, chain and tensioner fitted. Part 4: Cylinder Head Porting & Rebuild With the head fully stripped I decided that I would give porting it a go. Having built, tuned and raced 2 stroke bikes in the past some of the techniques and principles were transferable. If it turns out to be no good its not the end of the world but without trial and error there will be no further development! Before setting to work I decided to quickly knock up a stand to allow me to work on the head easier. Exhaust port, before and after Inlets again before and after Made a quick and easy valve stand to keep them in their corresponding positions And turned up a tool to help with the installation of the stem seals Ready to go! All finished
Part 5: Engine Assembly Fully built Part 6: Fuel Rail Had a spare few hours one evening and some left over stock from a previous project so knocked up a new fuel rail. Made a start on a new intake plenum, still trying to work out exactly what I want to do with this so Ive shelved it for the time being. A friend of a friend done the welding so I cant take any credit for that work. Hes done a brilliant job considering the materials involved. Part 7: The Haldex running gear jig With the intention of utilising the running gear from an Audi TT I decided the easiest way to transfer the mounting points would be to create a negative jig and use this to locate the mounts under the mk2 chassis. A friend of mine had bought a TT a couple of years previous and had done nothing with it so decided to sell it to me. 1300 lighter I had a complete car! A very tatty TT but all the running gear was spot on and the 02M 6sp gearbox was also there. I managed to sell on almost everything over the next couple of weeks and pretty much made my money back and kept all the running gear, engine (good spare) and gearbox. With the TT on its roof I began to start turning and fabricating the necessary parts for the jig Late night selfie Front turrets position And finished! Ignore what looks like a bit on the ****, thats a separate jig for the engine mounts. Part 8: The MK2 shell! With the Haldex jig finished and the TT body shell weighed in for around 50p I searched for a few weeks to find the most solid MK2 shell I could find. This is what I came up with. Apart from the missing doors and wings it really is a good shell. Potentially needs a new scuttle panel if I am being really fussy. I will get some new pics once Ive steam cleaned it and got it up to my workshop. Floors are certainly hole free And that is where I am up to! More to come over the next few weeks and months. Im aiming for ultimate dubs 2016 Sean
Such a great build. I wish I had the skills, time and money to do something similar. Will be following and watching this with interest. Keep up the great work.
Thanks guys seen sambos lupo at Santa pod and it's a weapon! Certainly one of the cars that's inspired me to build this little beastie. Will hopefully drop the 8v lump out of the mk2 over the weekend and start building a roll over jig for it.
I approve of this thread! Am also very jealous of you machining skills. Just out out interest, what boost do you think you'll need to run the GTX at to hit 450bhp? Keep the updates coming.
Self taught lathe and milling skills, nothing flash As for the boost, I'm not entirely sure. The turbo itself came from a friends 20vt which made 440odd on a base map. I'll see if I can pull some more details from him. He's moved up to a 3076 now and is knocking on the doors of 550
Update time! Today I finally got stuck in with stripping what wasnt already off the shell when I bought it, engine, gearbox, exhaust, heater matrix etc. Few pics before Bonnet has certainly seen better days. Guess itll have to be a carbon replacement And a few from a couple of hours later. Surprisingly nothing help up a fight The only 2 pieces of rust/rot that will need to be addressed is the scuttle panel which I was aware of. The other being due to a knackered engine mount allowing the downpipe to come into contact with the firewall. Eventually wearing through and then the moisture being trapped in the sound deadening finished it off. Either way its a pretty straightforward fix. Thats it for now
