MK2 Edition One 16vG60 project

I own a 1990 Golf G60 edition one. pics and spec below. But i have always want ted to make it proper mint and turn it into a 16vg60 in edition one spec.

Engine

 1.8 8v G60
 Stage 4 supercharger
 68mm pulley
 Chip
 Stainless steel custom exhaust
 De-cat exhaust
 Jabbasport induction kit
 New engine and gearbox mounts

Exterior

 Standard mk2 golf G60 body
 Smoked crosshair crystal headlights
 Smoked LED indicators
 Smoked crystal fog lights (to be fitted soon)
 Smoked crystal M3 rear lamps
 Colour coded wiper arms
 Lay flat rear wiper
 Wolfsburg edition badges
 Chromolux glass
 Cl grill with black vw badge
 Wolfsburg number plate surrounds
 Porsche polished handles

Chassis

 BBS RM split rims with 2 stainless outers, centers powder coated black
 G60 steels
 SPAX RSX coilovers
 Poly bushes
 Brembo discs
 Pagid fast road pads
 New suspension top mounts

Interior

 Blue electric cloth RECARO seats
 Wolfsburg gear dangling rhubarb
 Wolfsburg door pins
 Mk3 chrome door pulls
 Boost gauge mounted in fischer centre console
 MPH speedo conversion

ICE

 kenwood dvd headunit
 kenwood 12" sub
 kenwood 4 channel amp
 kenwood 2 channel amp
 kenwood components 6"
 kenwood bluetooth kit









I am really worried i will get things wrong so i have labeled every single electrical connection, and bagged and tagged every single nut, bolt and washer. All the nuts and bolts will be replaced with stainless steel ones or zinc plated were i cant get replacments.

engine has been pulled (my mate thought it would look good with a audi employee in the pic) :roll:



most of the interior is out along with the dash and the front suspension is in bits.

Currently colllecting all the bits that need cleaning, blasting and powdercoating to get the rolling front chassis put together so i can turn the car around and do the back end, when all thats done it will go off to be repaired and paint.

sand blasted and zinc primered parts







cleaned, etched primed and undersealed arches



sound deadened front footwells and dash area



bush set from GSF after i cut the old ones out the wishbones



and this is what 500 worth of genuine VW parts look like, pathetic really



Quick list of new parts

Gearbox end plate
power steering fluid res
all suspension bolts
most engine bolts and nuts
driveshaft bolts
rain tray
brake clips
side skirt brackets
coolant flanges
all new sensors
gaskets
ecu hose
cross member rubbers





ARP head studs i there too

 

found this



but managed to finish the engine bay



also picked these up from the blasters





and my home recon'd starter motor



Also had the guy thats painting the car round to have a proper look at the motor, pretty sure he can blow my socks off with the end result, sounds reassuring.

off to VW agian tomorrow to pick up VR6 sachs clutch, brand new door seals, HT lead guide tube, and all manner of parts to rebuild the gear selector tower. think i need therepy.

Before my car came off the road to be stripped down a problem developed with the ABS system, like it wern't working.

I stripped it down to find the cable feeding the motor on the pump had become broken from the terminal of the motor. Some solder and a test across the terminals from a battery and it worked. yeehaa

next i saved myself a few quid by rebuilding the clutch master cylinder, found nothing wrong at all, so painted, lubed and rebuilt. all ok.

I managed to deliver all the parts i had sandblasted to the powdercoaters about 11am. Then to my surprise the guy called me at 5pm to say all my stuff was ready to pick up, said its because he new i only had one day off, sweet.





more sandblasted bits



new outer cv's



built front crossmember





polybushed font with new VAG bolts





powdercoated rocker too



this is not what you want your crank pulley to look like.



had to grind down the pulley bolt to get the crank off, i hate working on 20 year old engines.

but it did come off



got the powersteering rack refurbed and put back on the car, stripped the sound deadening and stuff from the bonnet, put the panels on the front of the car and bolted some wheels on. then......




and cut my windscreen out, it took me over and hour and a half.



After i got it back in the garage i jacked the back up and chucked some axle stands under it, unbolted the rear bumper and started to cry, why why why did i decide it would be a good idea to poke my car

this sucks





guess more welding will take place

on another note, dont forget to prop the fuel tank before unbolting the straps

bump on the head

 

found some wiring issues between the body and boot lid



I also decided what i will trim the roof lining and A,B,C pillars in, and this is a comparison shot.



After shots of fully trimmed trim parts.





Stripped down the rad fan and painted, cleaned and assembled. Bolted together with stainless nyloc nuts and washers.





O and the car put back on all four wheels







And then........................











she's gone to paint

Had another trip to the powdercoaters and ended up with some nice looking bits



close ups of some of the parts





got more to show ya'll

rear beam, tank straps and front ARB



check out the reflection on the tank straps



and a few of the beam







driveshafts came up good









guess te bonnet had a few stonechips



should be back in a couple of weeks

Other than that just trying to tidy the garage and sort all the crap out.

buying more stuff from VW and generally getting stuff stocked to build the car when its back

thought i would show you al some of the work thats been going on

All new parts are genuine VW

expansion tanks mounted on refurbed mount with new bolts



New fuel filter with refurbed brackets and s/s fasteners



New foliage catcher for blower intake



HT lead tube and clips



Refurbed mounting plate with refurbed Master cylinder and new clutch fluid transfr tube



Cleaned, pressure tested and painted original intercooler



Re-cored and painted radiator

 

Looks like it will be a very interesting project

 

great build and attention to detail

pete

 

WOW!!!! that will be a seriously desirable mk2 when your done!!!

 

Yeah!! I do like that LOTS!!!

 

awesome, i love builds like this, far better than blinged up show tat.

 

indeed! some reall attention to detail!

bet your local powdercoaters love you!

 

Stunning effort all round, gonna be a beaut when finished, 16v g60 being the icing on the cake!

 

Top banana. Added to favourites for one to watch in the future.

 

Nice. Looks very thourough.

 

thanks very much everyone

i have more to show too, car is back from paint tomorrow

want it to look like a brand new factory ed1 16vg60

thats the plan anyway

 

Good project. Gives me the kick up the bum to get on with mine!

 

Its looking great! I want.......

..... Actually, I think you should sell it when you're done

 

Thats brilliant work - bet your happy putting back together all those nice clean parts...

 

Threads like these always put a smile on my face. Keep the updates coming!

 

Awesome. Thats going to be some car when done and should last another 20 years with ease. Good job.

 

Love reading all your comments.

I have been on this since june and been working on it a couple of nights a week, sometime till 2 am, with a 5am start for work. I have owned it for 6 years and would never sell it, sorry Adam, i think it deserved it after the abuse i give her an will continue too aswell. Its important to me that the car is as functional as possible i dont care for the show aspect of it to much but its a handy by-product of making eveything more durable.

heres the latest

Well i have ordered some WOSSNER 81.5 pistons for the engine so should be here soon, i can then send the block off to be bored.

Also bought all new genuine G60 trim/arches from VW, not cheap at all, current spend on everything stands at over 6k.

I broke a small drive cam in my abs pump so needed a replacment, bought a complete second hand unit from a member off dubforce, will be finishing the rebuild of my ABS unit soon.

Power steering pump is also back from being refurb'd. bloke said it was very worn and scored, expected a second rate service cause it was cheap, but i got the unit back with a bag of knackered internals, everything has been replaced for new happy days, finish was excellent too

And the big one

Got the motor back from my painter, poor camera phone pics sorry, car still has polish on it too











more pics of the other stuff i have been doing will come next week.

cheers all