MK2 GTI 20v Home build - air intake changes

Discussion in 'Members Gallery' started by cupracraig, Mar 5, 2018.

  1. cupracraig

    cupracraig Paid Member Paid Member

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    Hi, i thought i'd post my progress as i've been looking at this forum for a while and the facebook page and thought i'd share my journey on my MK2.

    well i picked up a 1991 8v back 2 1/2 years ago.

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    I drove it about for some time and then decided on some maintenance and a change to 20v. i've skipped a lot but here's some of the journey.

    The front drivers side wishbone joint was looking a bit sorry for itself :o

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    so ive added on some S2 twin pots
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    changed the charge pipe setup for that of a k04
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    new genuine mounts:
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    got it all in the car
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    a couple of nights of work and its back like this:
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    just loosly put in the new subframe while i clean up the engine bay and the old power steering rack
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    the new daily :violin:
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    also ordered a new trackslag exhaust , the slanty tip one to look OEM.

    its no longer my daily driver but also not a show car


    this was from 2017 Volksfest


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    Cooling sorted, plumbed, bled..ready to drive! now for some dry weather


    painted my intercooler pipes and fitted a new larger radiator. Just waiting on the fan bracket so that i can add the fan and fill it up with coolant again.

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    Cooling sorted, plumbed, bled..ready to drive! now for some dry weather
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    i replaced the fuel tank straps with new stainless ones :


    [​IMG]20171022_144829 by Cragmire40D, on Flickr
    [​IMG]20171022_144839 by Cragmire40D, on Flickr


    the mounting points were very clean

    [​IMG]20171022_142710 by Cragmire40D, on Flickr

    had the original RA wheels refurbished and new tyres all over

    [​IMG]20171030_213752 by Cragmire40D, on Flickr

    drove it a few times before the weather got bad

    [​IMG]20171103_113817 by Cragmire40D, on Flickr


    Built a false floor for a bit more sound

    [​IMG]IMG_20180122_200616_046 by Cragmire40D, on Flickr



    Decided to move away from the tapered bearing setup and go for a 6N2 GTI rear setup
    [​IMG]20180115_112944 by Cragmire40D, on Flickr


    then got excited and decided to just refurbish the whole rear axle


    Got a snapped bolt :(
    [​IMG]19905182_10156238860064258_4425863930378189923_n by Cragmire40D, on Flickr

    cut out the old bushes and housings

    [​IMG]20180203_223730 by Cragmire40D, on Flickr

    [​IMG]20180204_140736 by Cragmire40D, on Flickr

    Old bush vs new

    [​IMG]IMG_20180122_200839_578 by Cragmire40D, on Flickr
     
    Ari likes this.
  2. cupracraig

    cupracraig Paid Member Paid Member

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    Refurbished the mk2 rear calipers, adding stainless nipples with new covers and painted in Dark Anthracite which i will paint the fronts in too

    [​IMG]20180206_182456 by Cragmire40D, on Flickr

    [​IMG]20180206_182202 by Cragmire40D, on Flickr




    Brake lines replicated

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    rear beam blasted

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    Bumper removed and checked the area, looks really good
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    found a couple of little problems:
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    loose underseal removed and area prepped for new

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    Rear beam and brackets painted with Raptor Paint

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    https://farm5.staticflickr.com/4650/40450751952_030ddbeede_c.jpg[/img]



    Stripped down the rear ARB to bare metal as it seemed to have some worming under the powdercoat, painted with etch primer then Upol-Raptor, let it all cure for a week and i re-fitted it all with all new bushes.


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    Thats a summing up of progress so far, lots more to come

    thanks

    Craig
     
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  3. jmsheahan CGTI Graphics Designer

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    Looks great!

    Just done exactly the same polo conversion/beam refurb. Nice work :thumbup:
     
  4. cupracraig

    cupracraig Paid Member Paid Member

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    I figured its a really worth while conversion seeming as i'm doing the whole rear beam... just got to put it all back on now without scratching anything..it came off easier than i think it will go back on doing it single handed
     
  5. Tristan Forum Junkie

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    Lovely looking car.
    What do you think of the Raptor? I've gone off powder coated parts, especially suspension...
    I'm more inclined to use the likes of Owatrol and or Por15 now.

    But I've heard Raptor is very tough.
     
  6. cupracraig

    cupracraig Paid Member Paid Member

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    My initial impression is good. Its quick to activate so you have to be fairly quick when applying. I brushed it on and was pleased at how it applied, if you have access to a Schultz gun then that would also work very well. Por15 and Raptor were my choice for coating and Raptor actually came out cheaper and with better reviews at 21 delivered for 750ml and the 250ml activator.

    I tested the raptor on the work bench and its really really tough after 7 days, it took some elbow grease to scratch through it with a flat head screwdriver on a single layer, so the 3 layers should be more than enough to protect.

    The 1litre kit has been enough to do 3 coats on the rear beam, the beam mounting brackets and other associated parts.

    Remember to split it into 3 lots when painting i.e. 3 x 333ml (250ml Raptor + 83ml Activator).. if you mix it all in one go then it will cure and lump up in your bowl. So by splitting into 3 lots, you have time to work with it. it generally is touch dry in about 20 minutes from painting it on. then you can go over it again. But be sure to leave for 7 days to fully harden.
     
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  7. Rooster

    Rooster Paid Member Paid Member

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    Thanks for the summary, great work. The atlas grey looks great on a Mk2 GTI
     
  8. cupracraig

    cupracraig Paid Member Paid Member

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    thanks, its actually Pearl Grey but they do look very similar.


    Very fustrated this weekend that the caliper carrier bolts didnt arrive on Friday, so once i had replaced the rear hard lines i bolted up the stub axles and the dust shields and put the kettle on.

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    really annoyed as i could have had the car back on the ground this weekend.


    Now looking at braided clutch lines and also ordered a new pressurised brake bleeder
     
  9. cupracraig

    cupracraig Paid Member Paid Member

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    well after some parts turned up i got the rear brakes finished up and bled

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    I ordered up a braided clutch line to replace the OEM metal pipe one as i just wasnt keen on it

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    The cars now back on 4 wheels, so i need to re-connect up the mid section and back box so i can fire it up again. getting closer to using it again!



    still need to think about what i am going to do about the under side and some of the rust i have found. I dont have the space to use a rotissary so i could strip the underseal while the car is on jacks stands which i dont really fancy... or i can completely strip it down to a rolling shell and send it off for that work to be carried out...and while its at it, have it resprayed.. but i think thats going to be big money right?
     
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  10. cupracraig

    cupracraig Paid Member Paid Member

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    spent 30 minutes fitting the Trackslag exhaust back on lastnight and went to fire her up.....flat battery...

    so after an overnight charge at 12v 1amp i connected it up this morning before work and fired her up! got its good to have it running again after so many months!
     
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  11. cupracraig

    cupracraig Paid Member Paid Member

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  12. oldnick

    oldnick Paid Member Paid Member

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    That really does sound rather nice :)
     
  13. cupracraig

    cupracraig Paid Member Paid Member

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    The Trackslag exhaust hass been so good to listen to lately, echos so nicely up through the gorge
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  14. Savagesam

    Savagesam Moderator Moderator

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    Oooo very pretty! Wanna come and clean up my engine bay?

    I'm also loving the sound of the trackslag, most impressed.
     
  15. cupracraig

    cupracraig Paid Member Paid Member

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    i'm not really that happy with my own bay :cry: i want to put a polo or mk4 golf airbox in for the OEM look.. tuck the loom, move the battery to the boot etc etc etc etc.... the never ending list
     
  16. gasco

    gasco Paid Member Paid Member

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    That is one seriously good looking and sounding car. The gorge is always a good place with windows down for some exhaust acoustics. Keep up the good work i am sure you will eventually get to the end of your ever growing list.
     
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  17. cupracraig

    cupracraig Paid Member Paid Member

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    picked up some 1.5 and 2.5" lips for the RS's about a week ago. i've wanted to go a bit wider on them for a while so i've shifted the 1" rear lips to the front from the 0.5" that were on before and put the 1.5" lips on the rear.

    i did try on the 2.5" lips which made things a bit interesting..but too wide for the car

    [​IMG]IMG_20180518_213229_367 by Cragmire40D, on Flickr

    rears now look like this and look much nicer

    [​IMG]IMG_20180527_224645_575 by Cragmire40D, on Flickr
     
  18. cupracraig

    cupracraig Paid Member Paid Member

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    car all complete for the year and im trying to drive it as much as possible



    worked well as my wedding car :) 3 adults and my 2 kids in it and no rubbing


    [​IMG]IMG_3571 by Cragmire40D, on Flickr

    [​IMG]IMG_20180617_171944_919 by Cragmire40D, on Flickr

    Going to start talking to some places about paint and the rust under the window! going to replace the front windscreen too as its got 28 years of stone chips on it which is a bit grim in the sunshine
     
    Last edited: Jun 20, 2018
    Ari likes this.
  19. cupracraig

    cupracraig Paid Member Paid Member

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    not sure why the Flickr pics are not showing in my latest post
     
  20. cupracraig

    cupracraig Paid Member Paid Member

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    Took friday off and went for a day date with the wife, parked up at the pub, walked away from the car and she turns to me and says she really likes the golf and shes glad i have worked so hard on it. It was really nice to have come validation as i often just find myself saying im not happy with it or somethings not right. To be able to sit back and have someone you love say they are proud of your hard work was a really nice moment.

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