Mk2 GTi Syncro Build - Operation MOT

Discussion in 'Members Gallery' started by Savagesam, Jan 12, 2020.

  1. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    I haven’t really looked to be honest, I’ll take a look later.

    I don’t have a cat, I can’t fit a 3” exhaust through the the rack, prop at the engine unless I change the turbo to something top mount and have it run down the passenger side. In which case, it will fit.
     
  2. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    Bit more tunnel.

    EA2395D2-27B5-43D0-9782-B324980DB13F.jpeg



    999F8981-6BBB-408B-AAF9-E1CCD61114C0.jpeg

    and primed.

    B410710A-61D8-4B40-AC3B-AC9B61E3F677.jpeg

    Next part..

    5259E802-A60D-438F-B7B6-FF802914BAA1.jpeg

    It’s all fun and games!
     

    Attached Files:

    erreesse likes this.
  3. BISSONE Forum Member

    Joined:
    Jun 17, 2011
    Likes Received:
    24
    Location:
    South Staffs
    Getting there :thumbup: are you welding the other side as well or just going to seam seal or similar?
     
  4. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    Slowly!!

    You mean the inside? I’m not sure yet, I was tempted to run a bead on the inside. At worst case, I’ll run a few tack welds to hold it together as it’s double skinned then seam seal it all.
     
  5. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    Got my PAS rack fitted today, no clearance issues which is good. I started the downpipe again as I wasn’t happy with the clearance so now it’s much better. I need to finish that off, then finish the front of the tunnel.

    83811BB8-C0B1-4CC1-8507-1DC88696260D.jpeg

    New DP. Well part of it CB2098C5-3352-4C3F-BB8D-F287B5C8E094.jpeg

    99AAEB73-85F8-4666-BE3B-56E4F1CAEB78.jpeg

    new lambda position for better accessibility.

    19448292-2741-41C4-BB53-7C83AE971E52.jpeg
     
    erreesse likes this.
  6. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    Slowly chipping away at the welding, got the battery tray finished today.

    3 nasty patches

    05CB307D-338B-476A-BE8C-BA9EDD0502E5.jpeg

    Started on the spot welds

    0E403884-2A73-4913-A5A5-44C0DE42D825.jpeg

    And she’s out!

    C4CEE0F9-5FAF-4889-85B4-AACE1C51AA5F.jpeg

    cleaned and painted.

    2D542200-BEA5-4966-8BC6-04BA01526A30.jpeg

    battery holder thing removed as the battery is going to be hidden in the boot.

    056C82DB-A98D-42D8-9FE8-BBB484E154E8.jpeg

    Tadaaaa

    2D73074A-42FA-40AF-BD0B-958F77E74DD1.jpeg
     

    Attached Files:

    Steffen and erreesse like this.
  7. waj27 Forum Member

    Joined:
    May 22, 2009
    Likes Received:
    112
    Clean tidy job that! shell looks to be solid got much rust repair to do?
     
  8. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    Thanks, I’ve never done anything like it before!

    Nope, I had the couple of bits on the OS sill, got a small hole in the strut that was patched badly which I’ve got a cut coming for and that bit.
     
  9. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    Well I got some goodies today.

    FF29BF01-A961-4C4C-B89D-7AEE3290F519.jpeg

    That’s better, still a bit of fiddling but it’s much closer.

    EC086D94-4F31-4B6A-B29C-60AAC195488D.jpeg

    but It’s been messed with, so I’ll have to fix that.

    A1917B3D-2CBA-4626-AFA3-B1C4AB98EBB6.jpeg

    what’s wrong with people!?

    5DE576E3-D4EA-49ED-8C09-AC2BA4D21D39.jpeg
     
  10. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    Well I’m away as of Sunday so no work can be done, but I have decided to get ready for big power now and not further down the line.

    So it’ll be getting Haldex, and all the associated parts.

    One thing is, what shafts do people use? I’ve not looked into it yet but obviously the TT rear shafts are going to be too long and the Mk2 ones will be different
     
  11. Matt_16v New Member

    Joined:
    Jan 1, 2020
    Likes Received:
    2
    Love the fabrication on this, it’s intense!
     
    Savagesam likes this.
  12. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    Thanks, I’ve had good fun building it so far. Although got a few changes I’m going to make
     
  13. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    Well, I’m back from Amsterdam, Covid free and on furlough!

    While I was away, I decided to just do it properly so I set about finding a donor car. A TT was up for breaking down the road, and we came to a deal. Today we went and stripped it down.

    I’m going to utilise the newer style engine mounts and fabricate them in.

    More to come over the next few days!

    B726C58F-7E8F-4A24-99CD-1A8D6A36BFE7.jpeg
     
    erreesse likes this.
  14. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    Nothing much but got a bit done, ripped out the syncro stuff and got the new engine in.

    IMG-20200623-WA0028.jpeg

    Then back out,

    IMG_20200623_142921.jpg

    Then back in,

    MVIMG_20200623_155942.jpg

    Then back out,

    IMG_20200623_195823.jpg

    Then driveshaft problems..

    MVIMG_20200623_160533.jpg


    The engine is where I want it, so now I've got to box out the chassis leg, and build my mounts, trim the subframe down, that's all for tomorrow!
     
    erreesse likes this.
  15. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    She's in!

    Modified the subframe.

    IMG_20200624_101649_1.jpg

    You'd never know!

    IMG_20200624_104041.jpg

    So then I flattened the chassis leg to take the new mounts and popped it down and it sat low!

    IMG-20200624-WA0006.jpeg

    Up, up and away! I made some mounts for it.

    IMG_20200624_132136.jpg

    And about that much on the nearside.

    IMG_20200624_132151.jpg

    One stand made and welded up.

    IMG_20200624_164543.jpg

    Then welded up and positioned.

    IMG_20200624_164536.jpg

    Same on the other side.

    IMG_20200624_164543.jpg

    Happy with that, let's tack it up!

    IMG_20200624_194051.jpg

    And again, the other side. Need to finish welding the flat mount up on this side but nothing major.

    IMG_20200624_194044.jpg

    IMG_20200624_194224.jpg

    And plenty of space! I'm going to make my own cross support up though.

    IMG_20200624_131625.jpg
     

    Attached Files:

    Mk2daz and afbiker02 like this.
  16. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    It was an even slower day today but I made progress.

    Step 1, fitted the shifter:

    IMG_20200625_100910.jpg

    Although I think we've got a problem here IMG_20200625_101800.jpg

    Then I made a temporary dog bone to get the engine where I wanted for the prop.

    IMG_20200625_105106.jpg

    Then started on my Haldex bracket, epytec eat your heart out!

    MVIMG_20200625_130734.jpg

    Then up into a rough location

    IMG_20200625_154107.jpg

    Then aligned

    IMG_20200625_154113.jpg

    And then tacked, it's now part of the rear beam.

    IMG_20200625_173454.jpg

    IMG_20200625_192406.jpg

    My original mount isn't too far off. I'll have to make some stand-offs for then bolt it to the Haldex bracket.

    IMG_20200625_173619.jpg

    Anyone know the answer to this? The holes in the haldex, do you just drill and tap them out to m12? IMG_20200625_113612.jpg

    And 3 days later, nothing has changed..

    IMG_20200625_221657.jpg
     
  17. BISSONE Forum Member

    Joined:
    Jun 17, 2011
    Likes Received:
    24
    Location:
    South Staffs
    Looking really good mate, nice work! What guage steel are you using on all your mounts?
     
  18. rubjonny

    rubjonny Administrator Staff Member Admin

    Joined:
    Oct 31, 2003
    Likes Received:
    3,298
    Location:
    Bracknell
    I see you have an audi TT shifter, I was also looking at those. how do you find the gearstick position, as its shifted forward a bit compared to the usual 02j type
     
  19. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    Thanks! :)
    3mm, I did some research, and everyone seems to be using 3mm or less. It's adding some serious weight tho :(

    The chassis legs have box section underneath supporting it too so it doesn't attempt to bow.
     
  20. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    I do indeed. Although i couldn't tell you yet.. I just put it in the hole. I didn't even notice it until dad mentioned.
     

Share This Page

  1. This site uses cookies to help personalise content, tailor your experience and to keep you logged in if you register.
    By continuing to use this site, you are consenting to our use of cookies.
    Dismiss Notice