Mk2 Scirocco 1.8t RWD

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

  1. cupracraig

    cupracraig Paid Member Paid Member

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    damn...so much progress! excellent work
     
  2. dodgy

    dodgy Paid Member Paid Member

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    Please get a badge made for it -
    "Dagenham Edition "

    Have a look at some Peugeot discs, different offset options and sizes, v6 coupes had brembo calipers, , 4x108 Pcd too on most of it, even some citroen may be worth a look.
    Had a mix of 205 gti stuff on my minor, 1.6discs and 1.9 calipers, or vice versa, the caliper just needed a flat plate then to line up on kingpin surface precisely.
    May be worth a look at mondeo calipers, and focus st170 discs, think 300mm, and quite common to find calipers in breakers still.
     
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  3. Mk2daz

    Mk2daz Paid Member Paid Member

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    Totally behind on updates for this, not a huge amount has happened but i've been doing what I can whenever I can, i'll post update pics when i get some more time.

    At the moment I'm trying to suss out the flywheel/clutch combo for the 1.8T to rx8 box,

    I have a b6 a4 tdi starter motor which bolts up to the adapter plate which is fine, i now need to get a single mass flywheel and clutch pressure plate to match that will bolt up to the AGU, I'm looking at b6 a4 stuff but i've seen on a couple forums people have used a vr6 clutch kit with a g60 flywheel? didn't think the starter would work with that?

    Think I'll just stick to a b6 a4 diesel smf and clutch kit (will this 100% bolt up to an AGU?), but i'll swap out the friction disc for a cosworth heavy duty 240mm one or something along those lines, that should marry up to the rx8 gearbox input shaft.

    Are there any particular brands to go for on the flywheel and clutch kits? theres alot of cheap stuff on eBay thats probably a bit naff!
     
  4. Tristan

    Tristan Paid Member Paid Member

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    I'm always biased to Sachs, LUK, Borg n Beck etc.
     
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  5. Mk2daz

    Mk2daz Paid Member Paid Member

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  6. dodgy

    dodgy Paid Member Paid Member

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    Not sure of spline on clutch/rx8, from memory it's a sierra clutch so may be other ford stuff same fit.
    Ford owned mazda for a while, may still do, hence the 121 is fiesta and the probe was a mazda project.
    As for a single mass flywheel, search the g60 part number, as they are used in tdi dmf replacement, mine was actually a skoda fabia kit, used, paid 20 quid, or I believe a mk3 golf tdi is compatible. Then bought genuine vr6 clutch kit for the 1.8t fwd conversion.
    Presume a clutch slave cylinder will need thinking about too Daz, mondeo concentric ( sorry memory is a little hazy) fits over input shaft and is hydraulic, acts directly on clutch, fitting spacers are available, basically a nylon tube that went over the shaft guide, looked some ford specialist sites. I did a load of research on the moggy, machined a bellhousing and collected parts but never got round to fitting it.

    As an idea, it's this sort of thing, but transit uses similar and about £45.
    https://www.motorsport-tools.com/hy...t-gearbox.html?SID=o1c97uijeiei0l74la0qadq0q0


    Little read for you
    https://www.chamberofunderstanding....roject-changing-to-a-concentric-clutch-slave/
     
    Last edited: Mar 30, 2021
  7. Mk2daz

    Mk2daz Paid Member Paid Member

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    Nice, thanks for those links, especially that bottom one!

    RX8 clutch is 23 spline (same as Ford 23 spline stuff) and the 5 speeds are 225mm clutch whereas the 6 speed appear to be 235mm.

    As for the g60 flywheel, are the transverse application flywheels compatible with longitudinal starters? I have a b6 TDI starter that bolts up to my bell housing adapter and from memory it didnt match up the teeth on my std AGU flywheel. Not sure if i need a longitudinal specific flywheel, its all quite confusing

    Was planning on just using the rx8 clutch arm slave cylinder and release bearing, as the cylinder doesnt foul against anything as far as im aware but may not be just as simple as that. That bottom link is handy, there is guy thats producing similar kits but around £150, so the stuff in that link will be handy to know.

    Cheers
     
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  8. dodgy

    dodgy Paid Member Paid Member

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    Unsure of the flywheel compatibility, possible the by earlier diesel had dmf. For starter can you swap ends like old lucas stuff, had to build one for my old v4 from parts.
     
  9. Mk2daz

    Mk2daz Paid Member Paid Member

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    Brief update on this thing

    cosworth intercooler and rad now mounted, as are the twin 12" slim line ebay fans

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    made up a quick coolant hose sketch based off how i had it plumbed before in fwd form



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    coolant hoses now in place



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    as are the main boost pipes, would like to make up some ally ones eventually once i get better with the TIG



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    Moving on to the rear, was going to be using a ford atlas axle but it was just going to cost far too much to have a fully floating axle built up - a lot more than i could justify so the axle got pushed to one side for a bit.

    Started to look into other options, with my box being from an rx8 i thought it would be worth looking at what the rx8 rear setup was like. 4.44 factory 'torque sensing' LSD with an 8" crown wheel (atlas is 7.5"), beefy driveshafts that are good for 400+ bhp, 10 link suspension arms and a heavy duty subframe to bolt them up to. RX8's seem to be getting broken for parts virtually everywhere so parts are both cheap and fairly easy to get a hold of.

    There was a lad fairly local to me breaking his rx8 that he'd bought fancy adjustable arms and all that shit for, i went for a looky and ended up coming away with the full setup.

    the driveshafts are beefy as hell and the wheel bearings are huge too



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    subframe had been recently powdercoated too



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    rx8 rear discs are 302mm, mx5 mk3 is 280 and direct bolt on, i opted for the latter in the hopes of running a smaller wheel, more on that later

    Had the hubs and discs redrilled to 4 stud by RIchard at North East Brakes



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    Subframe came with no bushes, i wanted to paint it black before fitting new bushes and getting it fitted to the car, ended up painting most of the stuff, heres everything before assembling



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    Bushes all pressed in and diff mounted up, lifetime warranty on these ones from strongflex UK, highly reccomend for any car!



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    All assembled with random bolts and ready to be offered up



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    Floor cut out, had to chop out the chassis legs that run along the bottom of the rear tubs for suspension arms to clear, will be sure to completely reinforce this area



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    Tunnel was also cut out to be redesigned smaller and lighter, also makes it easier to set gearbox tailshaft and diff pinion angles.



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    Got everything sitting at roughly ride height, but didnt want to start the fabrication work until i had some wheels bolted up so ride height and centering of the subframe could be done accurately.

    offered up dads 15" revolution 5 spokes, 15x8 et0, brakes are a ball hair from touching but could be ground down a bit anyway, lower suspension arm mount is touching which is an issue, everything else only just clears!

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    Wanted to see what a bigger wheel might look like so I sourced some 17" team dynamic pro race 3's for a relatively good price as i quite like the classic 5 spoke motorsport style wheel.

    These easily clear everything but im very 50/50 on the look, sometimes i think they look ace and other times they just look too big for the car. The other option is 16s but then tire availability and price seems to be not as great for 16s. I'm quite determined to get a 15 that will clear, think the car is much more suited to 15s.



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    Whats everyones thoughts?

    15x8 et0 but will probably need to modify the knuckle and calipers to clear



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    or 17x7 et35 with no modifications required



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    Thats pretty much where I'm at, trying to decide which wheels to go for then I'll fabricate the chassis around the wheels.

    Other than that all thats left to do before i can fire up the engine again is:

    - turbo oil lines (need some from a b6 1.8t a4 for a direct fit i think!)

    - remote oil filter + cooler plumbed up and mounted somewhere

    - some modification to the sump to get rid of the 20 degree slant as my engine is sitting at 0 degrees vertical,

    - fire in the loom that i made up before.

    - need to suss out a clutch combination but theres an a4 1.8t solid mass flywheel bolted up just now for sake of starting the engine



    Cheers:)
     
    erreesse and dodgy like this.
  10. Savagesam

    Savagesam Moderator Staff Member Moderator

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    Looks great!

    what about 16”?
     
  11. Mk2daz

    Mk2daz Paid Member Paid Member

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    The reason I'm not to keen for 16" is down to tire prices and availability, given this thing is going to be ragged around a track quite often I think i'll be going through alot of tyres, so i'd like to keep that cost down if possible

    Quick scan on ebay looking at toyo R888r, all from the same seller

    195/50/15 £421.62
    205/45/16 £637.56 (!)
    205/40/17 £579.84
     
  12. dodgy

    dodgy Paid Member Paid Member

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    Great work Daz, looking at the prices on those tyres, it's only 15quid per tyre between 16 and 17, so not too shocking.
    I do like the 17s though, and you could upgrade brakes in time too if wanted.
     
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  13. Savagesam

    Savagesam Moderator Staff Member Moderator

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    Yeah I have to say, this is the reason I’ve ditched my 16” track wheels.

    I guess it’s a question of, is it worth the hassle to get the 15’s to fit?
     
  14. Mk2daz

    Mk2daz Paid Member Paid Member

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    Unfortunately havn't worked on this as much as i'd have liked to since the last updates...

    Spun a big end bearing in my other scirocco whilst doing the NC500 and as its my daily driver it needed sorted asap!

    Some pics from the trip before the car had to be trailered home early

    Eilean Donan Castle

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    Can't remember exactly where this was but the scenery was breathtaking!

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    Wild camping about 20 miles north of Ullapool

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    Back home and broken ABF out

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    80 quid AGU 1.8T freshened up and fired in and back on the road, sporting a few trick bolt ons, ko3s snail, fmic, 2.5" downpipe, oversized TIP, tuning technics remap, 02A w/ wavetrac LSD, hydro clutch, mk4 cable shifter, g60 brakes etc

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    On show at Castle Fraser couple weeks ago

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    goes really well and VCDS logs of air flow sensor seem to suggest ~230ish bhp which is plenty for a road car!

    Been getting back on to the rwd car over the last couple weeks and should have some nice updates to post very soon.
     
  15. Tristan

    Tristan Paid Member Paid Member

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    Great to see you back, Daz. So you went from ABF to 1.8t, just like that? Fair play
     
  16. Mk2daz

    Mk2daz Paid Member Paid Member

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    Cheers [:D] Went pretty flat out for a month or so on it to get it back on the road asap... Actually done part of the NC500 again in the car this weekend just passed so was nice to actually make it home in a scirocco this time, 1.8T serving me well so far.
     
  17. dodgy

    dodgy Paid Member Paid Member

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    Blimey Daz, thought you'd disappeared.
    Love the way you just dropped in the conversation a little 1.8t swap, and how it's sounded like a normal service. Mine took a few months to sort.
    How are you my friend? Can't wait for the rwd updates.
     
  18. Mk2daz

    Mk2daz Paid Member Paid Member

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    haha yeah - the easy part is getting the engine in, its all the little pipes and wiring etc that take up the time!

    I'm doing good thanks, hope you are well too.

    RWD updates coming soon :)
     
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  19. Savagesam

    Savagesam Moderator Staff Member Moderator

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    Let’s hope so too! I’m eagerly waiting!

    The Rocco looks great too [:D]
     
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  20. Mk2daz

    Mk2daz Paid Member Paid Member

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    Thanks mate!

    OK so back to the rwd car, its sat collecting dust for the past couple months so time to get back to it

    Main focus is getting the rx8 rear end in there bolted up supported under the cars own weight.
    I'd cut a great big massive hole in the boot to get it in place roughly where it needs to be, chassis rails had to be cut out too for the suspension arms to clear.

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    The subframe is a beast, and it needs to be to support all 10 suspension arms and the fat 8" diff etc! it takes 6 main M16 mounting points, along with two bolt on 'jacking plates' at the front, the cars structure needed to be strong enough to support all this under load! After a fair bit of humming and ho-ing, some cardboard sketches and some discussions with dad i decided on a 'cradle' design and got cracking.

    Time to get busy!

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    Made up some new chassis rails that would support the rear and central subframe mounts, welded in some sleeves like i done for the front rails prevent the tube from crushing as the bolts were tightened

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    welded in some bars to support these chassis rails, everything will be triangulated back to the original chassis rails too at some point for additional strength. The chassis rails are then welded to these bars (middle one has not been welded in just yet) and also welded to the cage mounting points, so everything is pretty sturdy back there. The front subframe mounting points are just some 8mm thick L shaped brackets i made up and have welded in to the exisiting chassis rails, these will be plated with gussets and tie up to the main bar for extra support, i think you can just make them out in the pics

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    for the coilovers i have some universal GAZ gold coilovers, these were specced for the car (although i can't remember what lb the springs are now!), the lower bush sleeves needed to be machined out slightly to sit perfectly on the rx8 knuckle, then for mounting them i basically made up a plate to extend the turret out a bit (keeping it double skinned) and welded in some lugs for the coilover to bolt too

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    After removing and fitting the whole subframe about 100 times i was able to finally bolt it all up and remove the engine crane, it was now supported purely by the weight of the car! This means that the only thing missing from the drivetrain now is a propshaft, and its going to be quite a short one too which is great.

    The diff doesn't look central here but thats because it is offset slightly due to the crown wheel and pinion, the actual pinion flange is as central and plumb as i could manage.

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    Next up is going to be building up the floorpan and gearbox tunnel again, i'll need to start making a downpipe before the tunnel is complete, steering column mounting frame, seat rails, bulkhead, clutch and flywheel combo, need to sort the front knuckles out as i'm looking to possibly change out the porsche stub axles after reading they are notoriously weak...hmmmm

    Also going to try and get some 16" wheels for it, i like the 17's but i think a 16" wheel would suit it much better and should still clear the brakes and knuckles etc no problem.

    Still loads to do, booked a week off work this week coming so will try and crack on as much as I can!
     

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