Hello Everyone, To clear the air before any comments on this thread, I know that what I am entailing is a "waste of money" by investing so much into a Golf Mk2. I am looking into taking my mk2 Golf with a 1.8L 8v, and a 5 speed transmission, and replacing it with a 1.8T 20v from a Mk3/4 golf as well as an 02J transmission. I've been reading through the site and various other resources, like Qpeng, and this seems like it's not too far of stretch. However, I would also like to position the setup to be able to take on a lot more power, but I would like advice on both. My overarching goal is to get the engine swapped and have a custom turbocharger setup to boost it to between 350-450 horsepower. From what I understand I will need the following to upgrade the Mk2 to a 1.8T and beyond: The donor engine - AGU or AUM if I understand correctly The donor transmission - 02J Engine Mounts - G60 Rear Brakes - perhaps from a Seat Ibiza Front Brakes - Same Ibiza setup? Suspension - Open to suggestions on which manufacturer to go with Radiator - An aftermarket Corrado radiator maybe? Intercooler - Probably a custom build for my purpose Clutch - From what I've seen Sachs seems to be the frontrunner Gearset - Would I need a stronger gear set for the higher HP ranges? Forged Pistons - Many suppliers, which ones are reputable Forged Connecting Rods - Same situation as pistons Improved Sleeves Bigger turbocharger - Something in the GT28 to GT30 range possibly? Piping and manifold to go with the turbo - Possibly one made for the 1.8T with some custom plumbing Wiring Loom - Rubjonny seems to be the go to for this situation, so I've already asked him about the setup Mk3 Subframe - I've read that this improves the handling Exhaust - custom the whole way back The exterior and interior of the car I would like to try to keep as stock as possible for the time being. If anything I've listed so far is terribly off, or anyone has their two cents to offer I would appreciate it!
i hope nut20v does not mind me tagging his build in this thread, but its looks the best fit for what your after... http://www.clubgti.com/showthread.php?245009-My-Mk2-GT30-Gone-for-mapping-What-Will-Come-Back you seem to have covered most of the things needed with 350+ bhp you will need an LSD. (figures you would expect from a gt28 or gt30) ASD/CTN gearboxes from mk3's have tall gears ideal gears. AGU blocks are pretty cheap if your looking to modify it (the way you are) also much simpler to work with. Seat ibiza brembos seem a good shout for stopping power but dont think they fit over 15's? Bigger injectors - definitely 'Rado VR radiator is good bit of a tight fit but still very good esp with twin fans For That sort of power i would look beyond your standard VR6 Clutch. R.J is the guy for Wiring looms - very helpful too That WILL be a money pit but there is no doubting it will be an absolute weapon once its built.
This imo is one of the best 1.8t builds you can read on here, it may not be geared for power bit the thought and quality that's gone into it you cannot knock! http://www.clubgti.com/showthread.php?196688-The-difficult-third-project&highlight=
Its time you started a build thread so people can chip in and give advise there is so much knowledge on here dont be afraid to ask even silly questions everyone has to start also i think the search function finally works so you can find most answers there
Doesn't sound like a waste of money or too optimistic at all mate, go for it, seen plenty crazier things pulled off RunJonny's looms are definitely worth a shout as you've already found out The AGU engines are winners in my book. Bigger inlet ports, good management, Mahle pistons, and no BAM/etc premium... throw some decent rods and exhaust valves in along with a freshen up (rings, bearings and the usual serviceables etc) and it'll take the power you want to give it Diff for sure though, don't even think about skipping it, it's a LOT of power in a Mk2, nothing like a chubby Mk4 or an S3 with Haldex's helping hand. I bought my A3 1.8T donor car for 350 as an MOT failure and ended up keeping the stuff needed for a conversion and made the best part of 700 from scrap, panels, interior, etc The rest is preference and there are a few ways of doing nearly every aspect of the swap so have a dig around RubJonny, Trackslag, Club GTI, tool box - All you need
for subframes it makes no odds what you choose for handling, they're the same basic shape mk2 and mk3. what matters is which 02a rear engine bracket you end up with as this is what dictates which subframe you nee. for example, corrado or g60 would require a mk2 subframe, mk3/seat abf or tdi would require a mk3 subframe rear brakes you can leave alone, what you have are already plenty good enough. the seat/polo ones are a better design as they have separate hubs but no real need to upgrade for the sake of it. I am though just because http://www.clubgti.com/showthread.php?177988 master cylinder the popular option these days is seat 20v/ford fucus 23mm unit as its shorter to clear the timing belt cover, it needs a couple mods to fit but these are well covered http://www.clubgti.com/showthread.php?248164
Hello, thought i'd stick my 2p's worth in on this one, it sounds like an interesting build in the offing Thanks Nealey for kind words and the link to my build. Hi Spooby, welcome to the forum, from your post count your pretty new here and its great to see you getting stuck into a project. Whats your car back ground? are you new to the VW scene? From your opening line you sound like you've had some bad internet forum experiences? Its all good generally round these parts, there are a lot of people who really know their stuff and they will be keen to help. I've posted my thoughts below yours below. Good your on board, get get a build thread started in the members gallery section. The donor engine - AGU or AUM if I understand correctly AGU The donor transmission - 02J Good choice, you'll need the shifter cables to suit the O2J Engine Mounts - G60 Good, or push the boat out to Vibra-technics Rear Brakes - perhaps from a Seat Ibiza Any of the Aluminium Mk4 golf platform rear callipers fit and are the best Front Brakes - Same Ibiza setup? Nothing smaller than 280mm with good quality discs and pads Suspension - Open to suggestions on which manufacturer to go with A good road set-up is fixed platform Koni adjustable dampers with Eibach Pro-springs with either Neuspeed or Eibach ARBs Radiator - An aftermarket Corrado radiator maybe? Don't get too carried away and don't loose site of the stock 16v Rad being double cored Intercooler - Probably a custom build for my purpose Yes custom build to suit is good Clutch - From what I've seen Sachs seems to be the frontrunner A VR6 clutch would be a good start with a G60 or Corrado 4cyl. flywheel Gearset - Would I need a stronger gear set for the higher HP ranges? Others i'm sure will give better advice than me Forged Pistons - Many suppliers, which ones are reputable I use Wossner pistons in my hi-rpm/hi-comp ABF track motor Forged Connecting Rods - Same situation as pistons Integrated Engineering con-rods all the way, they have 1/2" ARP bolts Improved Sleeves Others will have to comment Bigger turbocharger - Something in the GT28 to GT30 range possibly? PM Sambo on here, he's the Turbo mentalist Piping and manifold to go with the turbo - Possibly one made for the 1.8T with some custom plumbing Wiring Loom - Rubjonny seems to be the go to for this situation, so I've already asked him about the setup Rubjonny is the wiring god so he'll help with that Mk3 Subframe - I've read that this improves the handling Mk3 Subframe is practically the same as a mk2 and will make no difference if changed on its own, you will need the wide track suspension to improve the handling Exhaust - custom the whole way back Pipewerx are good Hope that helps. Cheers PAB
Thanks for the advice so far everyone. The Mk2 that have was purchased brand new in the United States in 1992, the wealthy lady who owned it later moved to Oxfordshire, where she currently resides. It has only done 44,000 miles in it's 22 years on this earth, and is in what I would say is impeccable condition. As it is from the US it is left hand drive and all other specifications that would go along with that. This will be my first project car and the first VW that I've owned. In the past I've had a slew of junky cars, but my current daily driver is a Nissan Note. I have however rented a VW anytime I've been on mainland Europe and love how they handle and feel. I love the idea of a beastly Mk2 because it's small, nimble, and very few people will expect it to overtake them. I know very little about cars, I've been trying to learn bits and pieces here and there, but I nowhere near competent with a torque wrench; I make my living doing IT work. I did find out in a hurry how impractical it would be to squeeze power out of a Note (hence my money pit intro), but this type of project has been shown to be possible, so I much more confident that this would be an alright idea. I'm working on a shopping list for parts, and will post it later.
ah with it being LHD you dont need to worry about the seat master cylinder, a normal mk2 22mm one will fit fine tons of clearance assuming its an 8v with 239mm brakes. if it has 256 already then you're sorted just put bigger calipers n carriers on the mc is already the larger version. if you want to go hydro clutch you'll need a metal strengthening plate from a lhd corrado or golf g60 as otherwise the bulkhead ends up a bit flexible, but a lhd 1.3 clutch cable and SEAT cable conversion kit should work fine if you dont want to go hydro. heres what it looks like, you'll find more info on the vortex http://www.clubgti.com/showthread.php?253479
Hello again everyone, I've been doing more reading and research and learned a few things and compiled a more complete part list of what I believe I'll need. Apparently VW used Mahle forged pistons in the 1.8T, which can withstand 450hp and they don't require sleeves like weaker engines. Connecting Rods - Integrated Engineering Forged Pistons - Wiseco ARP Bolts - IE Limited Slip Differential - Peloquin Stage 3+ Clutch and Steel Flywheel - Spec Corrado Radiator - VW Front, LH Rear, RH Rear, and bushes - VibraTechnics GTX3076R Turbocharger - Garrett Golf MK3 Gearbox -VW Shifter Cable kit for Mk4 Golf - VW Wiring Loom - Rjonny 1000cc Fuel Injectors - Delphi Intercooler - Mishimoto Intake Manifold - IE Exhaust - Custom Back Rear Brake Disc Conversion - VW/VW Heritage Steel Brakelines - No vendor looked into yet Coilover Setup - Koni Coated Tubular Exhaust Manifold - Custom Fuel Rail - IE Fuel Pump - Bosch Anti-sway bars - Eibach Adjustable Cam Gear - IE Fuel Pressure Regulator - Bosch Intake Valve Set - Supertech Valve Spring Set - Supertech Short Shifter Kit - VF Engineering Blow Off Valve - Tial Electronic Boost Controller - GReddy Turbo Wastegate - Precision Downpipe - Custom Wideband O2 Sensor - Innovate Camshaft Set - IE Headgasket - VW Oil Pump - VW Water Pump - VW If anyone thinks any of the brands/items I've listed so far are rubbish or not worth it, don't be afraid to pipe up.
Hello again everyone, In case anyone is still interested I'm still planning this conversion, and I've started ordering parts. After realizing the growing costs of all the parts once they have come together, I've decided to go with a traditional engine conversion at first, and focus on a ridiculously powerful setup later. The engine I've gone with the BAM code engine and a stock K04 for a respectable 225 hp. So far I believe I have every piece for the conversion on order, and I am just waiting on shipping for all the bits.
what i can see from your list is you havnt thought about your clutch operation of if you are going cable or hydraulic
I think I would prefer a cable clutch setup, but I need to do more research into what that would actually take. On a different note, does anyone know if the cable driven AEB throttle would work on the BAM engine?
Make your life a tiny bit easier and cheaper too, get a mk2 gti rear beam with discs on it already, then all the handbrake cables too If I read the start of your post correctly this is a regular 1.8 golf, WITHOUT rear discs Sent from my C6903 using Tapatalk
Yeah it's the version with rear drums, and I've already purchased a rear axle and some mk4 Golf calipers for it. I'm just waiting on the calipers to arrive. I'm also scouring ebay for a full set of G60 280mm brakes for the front.
