Mk2 Scirocco 1.8t RWD

Discussion in 'Members Gallery' started by Mk2daz, Mar 25, 2020.

  1. Mk2daz Forum Member

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    Ah now that is interesting! I have a Gas N Gears lightened/balanced G60 flywheel which would be ace if it can be used here! Not actually offered up any flywheel/clutch combo yet but the gent who made the plate suggested the combo i mentioned before, all i've done is mate up the box to the block. Thanks for the shout on the a6 starter, is it beefier than the a4 effort? As for the spigot bearing, shouldn't be an issue as the 06A blocks do not have one i believe (I'm using an AGU block which is an 06A), afaik only the longitudinal 058 blocks have them!
     
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  2. dodgy

    dodgy Paid Member Paid Member

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    Just seems to be more A6s than A4s turn up in breakers, or was last time was at them. would think starter is same, the exhaust downpipe, cat etc is same on the 1.9 diesel, but a6 is 130 compared to 115, and as said the earlier may be single mass rather than dual, my 07 was dual mass.
    Thinking aloud, there are 5 and 6 speed boxes on the audis, not sure if same starter, and Porsche boxster uses that style box, you use an A4 box if put a 1.8t in them.
    I'll see if can find part number for flywheel mate.
     
  3. dodgy

    dodgy Paid Member Paid Member

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    Found a similar discussion about flywheel, the g60 is a no go, but says a 1z tdi, but the longitudinal version. Possibly A4b5, passat 96 on and a6c5?
    There is a very odd looking item on ebay, from Germany, £19 plus 20 post!
     
  4. Mk2daz Forum Member

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    Nice one thanks for this info mate!

    To quote the guy who makes up the plates - "You can use it with a the 20v 1.8T engine too with a single mass pd flywheel and starter motor off an audi A4 you use the pd clutch pressure plate and a ford clutch friction plate."
     
  5. dodgy

    dodgy Paid Member Paid Member

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    Did see that, I looked up the company.
    Presume its starter and flywheel off A4, not a tdi flywheel and an A4 starter.?
    Haha, trust Dodgy Dave to confuse the situation.
    A4b5, passat 96 on and A6 are longitudinal and probably easier to find single mass, but you can get new set up for about 140.
    Ooh, you may be aware but the ford plate has several variations on centre spline and size, got a funny feeling from memory it's a specific cortina one that has right spline and outer dimensions.

    Seems 1.6 Sierra clutch is 190mm, interestingly vr6 clutch is 228mm as used with 1.8t g60 conversion usually, So is A4 tdi, the RX8 is 225, could you use that?
     
    Last edited: Nov 22, 2020
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  6. Mk2daz Forum Member

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    Yep I believe it is starter and SM flywheel off an A4. I will need to cross this bridge when I come to it, there are a few rx8s that have been converted to run VAG 1.8Ts so there must be a combo/combos that work, albeit a bit frankenstein!

    I've hit a bit of a barrier on what front suspension/hub setup to run now, I ideally want it to be 4x108 to match the PCD of the atlas axle halfshafts at the rear, I have bought some Porsche 924 uprights with the stub axle to do away with jamming the end of a CV through the scirocco hubs. The porsche stuff bolts right up to the scirocco wishbones, ball joints, tie rod ends etc but due to the absense of the driveshaft the strut mounting is alot lower - see pics below

    Scirocco

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    Porsche 924

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    Big brake options seem pretty slim for the 924 stuff, I was thinking with a very selective wheel bearing combination I could have used an alloy hub from something like a mk2 escort where the brake options are endless but I'm just not sure if thats going to work.

    Hmmmmm what to do now.....
     
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  7. dodgy

    dodgy Paid Member Paid Member

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    Hahaha, princess 4 pots, proper old school upgrade on a Ford, god I'm old.
    Mondeo st calipers and st170 focus discs think fit the sierra hub, definitely fit escorts, fiesta etc.
    Could have vr6 hubs drilled to 4x108, run with a modded cv joint and then cupra R brembo, 312 TT, Porsche etc calipers, and modded discs to suit.
    Suspension, how about coilovers wound up, or the 4wd mk2 golf? If you used vr6 wishbone can you use mk4 hubs, or even ibiza/polo/fabia, shock mounts differently to mk2/3 etc and think Octavia is compatible too, ie scout.
     
  8. Mk2daz Forum Member

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    I will need to look into that, There a number of rear disc conversion kits available that use cosworth rear calipers, I've also seen some with peugeot setups on the rear.

    If possible I would like to retain the scirocco front upright as I have these 300mm vented discs that i will redrill to 4x108, wilwood 4 pots and some brackets to bolt them to the scirocco upright.

    [​IMG]Untitled by Daz Scirocco, on Flickr

    So the next challenge is how can i can get a 4x108 front hub into the mk2 scirocco upright?!

    Dont think there is enough meat on the scirocco hubs to simply redrill to 4x108...hmmm

    [​IMG]Untitled by Daz Scirocco, on Flickr

    This build is all about problem solving now [:D]
     
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  9. Mk2daz Forum Member

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    Bit behind on updates with this, will try keep this brief!

    Decided to sort steering / suspension out before i finalise engine position

    Steering rack is from an old Porsche 924, and i've fitted it with mk3 non PAS tie rods, and mk2 tie rod ends

    This bolts to porsche 924 stub axles, and i've worked out that i can use mk2 escort front hubs (which my dad has had in the garage for about 30 years collecting dust) with a v6 capri wheel bearing kit. Will get some pics of this soon but this gives me the same ford 4x108 fitment to match the rear axle.

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    mk3 tie rods compared to mk1, nice and wide



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    made a custom crossmember to mount it such that the steering geometry is near enough perfect. Its quite oddly shaped at the front for sump clearance

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    Bolts to the chassis rails and the wishbone mounting points like so

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    Welded in these 'sleeves' to where the bolts go through the box section chassis rails to prevent them collpasing in as the bolts are torqued up

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    With crossmember and steering now in position the bulkhead was chopped out again and the engine was positioned as far forward as i could get it behind the crossmember. The size and position of the 1.8t 06A block oil pump was really the main issue here, the sump needs to be very deep at the front, hence the engine behind the crossmember rather than on top.

    Heres the final position, should help with handling and weight distribution

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    Started to make some mounts, engine will be mounted in three places - either side and in front too, i'd rather go overkill with this, still waiting for the last bush and bush sleeve to arrive so i can make the final one. Mock up steering shaft i made has been sent away down south to be fabricated/machined too, didn't trust myself welding one up, it would constantly be on my mind incase it was to snap under load, especially with no power steering and big wide wheels.

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    Bought a universal RX8 gearbox mount to give me a break from welding

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    Re-inforced the floorpan either side where it bolts up and then got it fitted (need to get some smaller high tensile bolts), and for the first time was able to lift the car with the engine and box attached, everything is about as central and straight as i could have hoped for



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    Fired on some of dads old wheels to mock up track width etc, these wheels are 8J with pretty crazy offset, the rear will poke a bit more once the brakes etc are on



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    And with some knackered old wide arches taped on.

    Theres a boy on the scirocco groups developing berg cup kits as we speak so i'm thinking of going for one of those.

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    More to come, cheers [​IMG]
     
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  10. Tristan Forum Junkie

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    That's an utterly awesome update.

    Love that Ford bearing thing working out for you, that's cool.
     
  11. Savagesam

    Savagesam Moderator Staff Member Moderator

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    Indeed. I love it!!
     
  12. dodgy

    dodgy Paid Member Paid Member

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    Great work Daz, looked at the sleeves and thought they were those nitrous oxide drinks things at first!
    With the mk2 escort hubs are you able to use more modern calipers such as st170/ mondeo v6 or old school with princess 4 pots?
    Nice front crossmember, not too odd looking, wasnt the escort cup one similar? And will give a bit of protection for the sump.
     
  13. Mk2daz Forum Member

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    I need to start updating this more frequently, keep forgetting

    Bit more done on the rwd scirocco, the 3rd engine mount bush and sleeve finally arrived so was able to get the engine fully mounted in, as its only been on two mounts up until now

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    Crossmember is gusseted underneath like so

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    Heres a better picture to show the steering geometry, the tie rod ends aren't bolted up but this is roughly how it sits with the wheels straight, I'm really happy i took the time to dial this in before going any further before!

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    Dad bought this intercooler many years ago but in the end didn't use it and its been sat in the loft of the garage ever since, i believe its a sierra cosworth core, nice and thick, either way its made its way on to my car [:D] Mounted with rivnuts because i love rivnuts.

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    Custom steering shaft arrived, got a fabricator down south to tig weld it for me based on my mockup shaft i tacked together for him, chuffed with it, its a removable UJ on the steering rack end and i have a 20mm bulkhead style bearing for it to slide through up to the column.

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    Was looking into turbos and manifolds etc, went for a TFSI ko4-064, the manifold is built into the hotside so no messing about with manifolds and its also clocked correctly for the downpipe etc, this one also has a BBT anti surge billet wheel fitted which should help with boost onset and duration, should see a fairly reliable 350hp from this.

    To fit it to the 1.8T head an adapter plate is required, got this one from CB auto and its spot on, theres an AGU gasket on the head side and a tfsi gasket on the manifold side.

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    The next issue was with the column mounted in the original place it was extremely close to the downpipe flange of the turbo. After a bit of head scratching i decided i would use this to my advantage, i'll bring my seating position back even further allowing me to lower the steering column slightly, giving me enough room between the exhaust flange and the steering shaft.

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    Of course doing this would bring the UJ on the steering rack to quite an angle, more than 45 degrees which i wasnt too happy with, so the steering rack mounting points on my crossmember were tilted and rewelded to bring the column to rack UJ nearly straight with no angle, much better. Its a tight fit down there but it all works!

    I wont finalise the steering/seating/pedal position just yet until i have some seats, so I've ordered some seats (which took a while after 100s of measurements and emails!)

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    Was getting a bit tired of the surface rust on the front end, so took a weekend to clean it all back, repair any holes and then make some more with the swager tool, then etch primed the lot

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    Made up some inner wing gusset strengthening plates and welded them in, will swage hole these and use them for the front bonnet pins, which i've marked roughly with masking tape

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    Heres my crossmember in all its glory, drilled some holes in it before cleaning it up, etch priming and refitting

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    Also cleaned up the porsche 924 stub uprights and the mk2 escort front hubs, etch primed and sprayed gloss black

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    Won a big VW diesel starter for 4 quid on ebay, no idea if its the right one for use with the rx8 box yet but its an absolute beast!

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    Chucked on doors and tailgate etc and started working on some of the panel gaps, for being a scrapper they are actually pretty good! Started sanding back some of the paint, especially the passenger door as it has been very poorly resprayed before at some point.

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    Started mucking about with some cardboard after considering the idea of making my own widebody, not really sure if i'll do this or not, would be good to find a full zender z400 kit but thats just not going to happen!

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    Managed to convince dad to let me unbolt his fully floating atlas axle and group 4 wheels and try them up under my car, when you get these axles built up you can pretty much have them made to any size you like, the halfshafts are all machined to suit any length tubing

    Seeing it like this got me pretty excited, im hoping to have my axle sent away soon for some thicker tubing, uprated halfshafts etc, will need to go an inch wider either side at the rear, or a less wide wheel on the front, these are 8s all round

    Gonna need to do alot of fab work to raise the boot floor where the axle is going to move up and down, and also notch the wheel tubs, nothing i wasn't expecting though.

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    Moving back to the engine side of things, I wanted to sort out the radiator so i could start plumbing up coolant hoses etc, tried a couple different radiators from various VWs before opting for this cosworth alloy one, its the same size as a vr6 rad but with a thicker core, and its much cheaper too, the bottom rad hose is on the wrong side for me but i can live with that. The side mounts are perfect for mounting to my box section chassis leg supports.


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    Mounted sandwiched between two 10mm go kart seat rubber mounts and a M8 rivnut, and a couple of small brackets to secure it to the intercooler up top

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    Coolant lines are slowly starting to come together, just a few left to sort out, intercooler pipework temporarily mocked up with some scrap bits of hose and pipework i had left over just to see how it may look, think i need to play with the turbo side intercooler outlet, its point down quite alot.

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    Heres the next issue im tackling, the original bonnet hinges dont work because of the cage, got a couple ideas for that which I'll hopefully suss out in the near future.

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    Cheers for reading, more to come :)
     
    Last edited: Jan 30, 2021
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  14. Savagesam

    Savagesam Moderator Staff Member Moderator

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    Oh damn. I love reading this.

    I’ll be excited to see it on track one day.

    Keep it up :)
     
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  15. Tristan Forum Junkie

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    Totally brilliant update!
     
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  16. dodgy

    dodgy Paid Member Paid Member

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    Excellent work daz, really great fabrication and although I'm nearly 50, I still snigger at the word Gusset.
     
  17. Mk2daz Forum Member

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    Sh*t, just realised the front hubs i've planned to use are in fact not from a mk2 escort, but from a 3.0 capri!

    Tried some hubs from a mk2 rs2000, totally different bearings...

    Looks like i'll need to go back to the drawing board, or find a big brake kit for a v6 capri (not likely!)

    More head scratching ahead...!
     
  18. Savagesam

    Savagesam Moderator Staff Member Moderator

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    Could you not just get some caliper adapters machines to whatever you want?
     
  19. Mk2daz Forum Member

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    Thats what i plan to do, the problem is now finding some big discs suitable for whichever hub i go for as theres F all available for a 3.0 capri! hub needs to be able to fit the porsche stub axle using certain sized bearings, disc also needs to be able to clear the steering arm and caliper carrier mounting points of the knuckle.

    Guess i could have custom brake disc bells made up...
     
  20. Savagesam

    Savagesam Moderator Staff Member Moderator

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    Sounds like you need some custom floating discs
     

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