Mk2 GTi Syncro Build - Operation MOT

He buys them in apparently. It’s a new batch he hasn’t tried so my guess is that they’re wrong. Thread pitch is definitely off.

Which has ruined my week tbh. I was hoping for some good progress next weekend

 

Managed to get a bit done, not much left before it’ll fire up.

Intercooler fits with the rad in factory holes.


Then I got evicted…



Managed to get the engine mostly plumbed up.



almost looks like a car…



and the quad grill fits…



next up is figure out the fuel pump wiring, Mr Newman, I didn’t really understand your instructions…

 

ok so. see the white plug there, chop it off.

splice the outer pins on your mk3 fuel pump plug to the red/yellow and brown wires from the fusebox. splice mk3 purple/black to mk2 purple black, and brown/blue splice to the thick brown. job done

 

And this is why you’re the greatest.

 

A new, freshly made piece of magic turned up today. We’ll.. I collected it.





Now to get welding

 

Yep

 

Nothing exciting but it really feels like I’m moving in the right direction.

Front brakes and clutch are now finished.

Made up the rear arm hard pipes, managed to get both sides looking pretty symmetrical which is nice.



Then made a start on the front to back lines, got my left bias valve plumbed in, just need to make a bracket so it doesn’t flop around.



Front to back is relatively straight. My clips didn’t arrive so I’ve got a couple of old ones.



It’s much nicer being under the car than looking at the top. Got a new diff, so when that comes out I’ll paint the brackets and fit a new bush.

 

Because I don’t pay for this stuff and I won’t keep the car long enough for it to matter

 

I have a feeling I won’t like it when it’s done. I hope that’s not the case.

If I did sell it, I’d go buy myself a Porsche.

 

Once I’ve made a couple of brackets, will be golden. But otherwise the brakes are finished. If I wanted, I could bleed them up and even have a working hand brake.





I’ve managed to relocate the PAS bottle, so I can keep the PAS. I’m rapidly running out of space in the engine bay.

I still need to:

Route the wiring and loom tape it,
Build an inlet,
Weld in MAP sensor,
Modify manifold to accept wastegate & weld into the exhaust,
Weld in Lambda bung,
Make brackets for the intercooler,
Make brackets for the radiator,
Fit wiper mech,
Make a bracket and pipe in the catch can.

I *think* that’s it for the engine bay.

I’ll weld up the fuel tank over the next couple of weeks, and my MAP sensor pipe.

I need to finish putting the interior back together, fit vacuum lines for the central locking, 3D print some cases for the haldex controller and wire that in, modify the fuel pump wiring. Fit my canchecked thing into my clocks.

Bleed the brakes, adjust the bias valves on the brake rollers.

Do a massive wheel spin and hope it doesn’t bend a rod

 

Because I don’t want to drill holes to have them in the car, once they’re set up they’ll never be touched and trying to find a syncro bias valve and associated fittings is almost impossible. I’ve been keeping my eyes peeled for the past 2 years and still haven’t found one so this was the last solution.

 

They aren’t fitted for the adjustable aspect, only because I can’t get OEM parts. So I’ll set them up and never touch them again. I have no interest in adjusting them.

 

Not pretty but meh, welded the boss onto a boost pipe. Just to bead roll it now.