Mid VR6 MKI Scirocco

[woody16v]

i have loved every single update to this thread but hearing it start for the first time was most excellent!
especially the way everything is thought out and planned then executed, love seeing the CAD stuff (did some of that in h.s. and college so its fun to see) great job sir.

cant wait to see this in person!!!

[Glitch481]

This thread made me actually get an account just so I could complain! I was looking forward to seeing a finished car on page nine!! LOL!
But you are doing a great job! And if you have the time can you send me the pics of the CAD screen shots so I can blow them up to look at them better?

Also, what are you going to do with the Intake? How are you going to mount that?

[laminaytrap]

Benny!

Where are the updates???

Jon

[garasja]

You doing a great job. Check out my rwd project.

[vwkid_Zach]

Aquired the following parts:
- complete timing chain kit
- metal head gasket
- all new seals
- new head bolts
- new crack pipe
- lightened the flywheel
- unorthodox pulley clones (crank and alt pulley)
- 268 Cat cams

Oh so thats how you learn all this CAD mumbo jumbo.... pass the pipe bud. We all want a Mid engine VR6 rocco now

Zach

[All Eyez on me]

Found this thread here today...and what should I say?

DAMN THIS IST HOT!!!

One of the most indcredible builds I´ve ever seen. (And I have seen a lot of builds in my life...)

How do you pay the cost for those builds? With a normally job you can´t do something like this here in germany...

Impressed regards...

[BennyB]

Just a quick note to confirm that I'm not dead, and I still think about this project every day! I found a house with more suitable shop space - 28x30 with a loft for storage and a lean off the side to store 2 more cars. But that requires selling this house which has been alot of work lately. I've been purposefully avoining vwvortex because it's a time vortex, but I miss everyone!

[cabrlicious]

cmon benny sell that house, build that car.

[garasja]

what happen with this project? give us a update please

[mk1daily]

what happen with this project? give us a update please

Project looks amazing

[atoson]

If anyone notices that this thread started in 2006. Let's just give this guy the credit he truly deserves specially if gets this rolling.

[punchbug]

If anyone notices that this thread started in 2006. Let's just give this guy the credit he truly deserves specially if gets this rolling.

I recall going with Ben way back in the day to get a pair of LSDs and gettting messed up at the border. He had that car then and I sincerely doubt that he'll be ignoring it any time soon. I just had the one Scirocco the first time I saw that car, and at that time he'd just done the heroic overnight marathon 16V swap with friend who also did one. So once he gets his housing settled, I'd expect this build to make huge advances very quickly. Best of luck with it Ben!

[BennyB]

hey, I'm still alive. The new place needs some work, but part of that was the electrical line I just finished out to the garage. It was only 220V 30 amp on 12 gauge before, now I'm cookin' with 220V 100amp on 3gauge wires! Various welder and machinery hookups still needed.

There's tons more space, all of it seems to be occupied by all the junk I had in 1/4 the area at the last place. It will take some time to get organized.

No height for a hoist, but I'm thankful for the 2nd floor storage instead and the car is sitting over a pit. Never used a pit before, I'm sure it will help. Once I get everything sorted, there will be lots of room to get things done quick!




I was going to put a big push on, but we decided import an '83 Westy from California to BC and drive it back to Ontario. Should be a fun trip with the family!

[.T.o.n.y.]

Looks awesome.

[sciroccokidJ]

hey im thinkn about doin the same thing i have n 86' scirocco and i got the vr6 motor from a 94 golf gli but i've seen the motor put in the front lik usual so to c it how ur goin is gonna b unique u got props from me!!! :p keep us posted.

[TREKSportMK3]

just had to bump this, hope we can see it get finished soon, ive thought about some crazy projects, but the in depth detail youve put into this is so intense, my mind cant even follow, and its abstract!

[WRC_413X]

Insane project, i always love seeing someone go out of the standard engineering mod comfort zone and making it whatever they want!

[BennyB]

Time to revive the thread. Now that I finally finished writing my master's thesis, I can work on the car again guilt free! There are some cool parts I've picked up along the way that I should get pictures of (aluminum fuel tank, Bosch 044 pump, Wilwood front brakes and adapters, clutch master)

The Task list:

hydraulic clutch pedal

master mount
get linkage clip holder
acquire line for fitting calculations
fabricate line and mounts

M14 LH lock nuts
Build rear cage/closeout
exhaust

get V-band clamp
get muffler
build downpipe
build tailpipes
muffler hangers
02 sensor bungs

cooling system

purchase heater core bypass
source alt/water pump belt
front rad mounts
front rad lines and mounts
coolant reservoir mount and plumbing
rad fan wiring
main rad plumbing
heater core plumbing
coolant temp

electrical

battery mount
starter wiring
engine wiring
ECU mount
electronic throttle pedal
tach signal
speedo driver
oil temp
alternator light
oil pressure light
MIL light
OBD connector

shifter linkage
modify half-shafts
suspension

fix front cross mount
subframe
rear supports
cross support
tie rod mount top braces
bolts or isolation mounts
rocker arms
rocker arm mounts
upper damper eyelets
lower damper eyelets
pushrods
pushrod mounts
design ARB

fuel system

tank mounts
pump/filter mount
pump wiring
make -6AN to M14x1.5 and M12x1.5 fittings
fuel lines
fuel level sender

wheels\tires

source tires
machine wheel centers
build wheels
get tuner bolts?

rear brakes

Source rear spot calipers
design/build rear spot caliper mount

remake tie rod threaded adjuster

[TBerk]

Tanna Leaves to you my friend, welcome back!

[BennyB]

Yes, it has been a while. Other mid engine MK1 Sciroccos have been built in my absence!

Here is the 11gal (40L) aluminum tank I happened to find that was exactly what I was looking for. I wanted something rearward mounted and tall in the front, so there was room between it and the radiator for a 'crush zone' in an accident.



so that spawned getting some pieces for the fuel system sorted out.
Bosch 0 580 254 044. Minumum flow at 5bar operating pressure = 300 Litres per hour and good for 700hp. M18x1.5 inlet threads, M12x1.5 outlet. I ordered the M18x1.5 to -8AN adapter for the inlet and a screen filter to keep the big junk out of the pump. I'm still sorting out the pump to filter connection. I might just use the banjo bolts somehow, since that way I can use the check valve on the pump outlet. I'm just concerned about the flow restriction with the banjo fittings. I made an adapter for the other side of the filter to the push-on MK4 fuel line fitting.

[BennyB]

I haven't done any CAD in a while, so it was fun to get back into it with a MK4 clutch master:

[BennyB]

Making an M12 banjo bolt to 3/8"ID hose adapter for the fuel pump. Temporary, until I can order some -6AN fittings

Starting with some 3/4" aluminum hex stock, I cut the nipple part and crucially, a 60deg angle


Here's where it gets interesting. Lining it up took some fussing about. I needed a bit more taken taken off the angled part to center it better


cut the face, drill it out. I had pre-drilled into the center when I made the nipple, which was a mistake since the drill bit wobbled when it encountered the sideways hole. Next time I would only drill it part way and then just hand drill out the last bit.


I didn't really have a good tool to cut the relief on the inside bore for the fuel to flow, but an internal thread tool wasn't bad.

Finished:


Made some for the fuel filter too, but much simpler


Got a 2.5" V-band clamp and 2.5" Magnaflow muffler for the exhaust. I still need to order some stainless bends though.


exhaust layout:


Lots to do still, but I want to get it briefly running again just so I know it isn't all seized up.

[BennyB]

I was working on some wiring last night. I am now lamenting having removed the battery tray when I relocated the battery to the trunk earlier in the car's life. Now the battery has to go back to the front.

I took the carpet out for now and removed sound deadening. I don't think it will do much sound isolation in that location with the engine in the back now! Floors are not good under the front seat mount.


Trifecta of bad wiring:


Had a black and white visitor(between door and stairs) while I was sitting at the fuse panel unwrapping wiring loom. he walked right by the open passenger side door and rooted around in the back of the shop for a while before getting bored and leaving.

[BennyB]

This beer kicks my ass, and makes it hard to get anything done. Any other tallboy after work and I don't even notice.


At least I hit the scrap yard and found the weird clutch master fitting:

[BennyB]

I've been working on the hydraulic clutch master and pedal mod. I used lots of info from FunkSoulKitty.org (thanks!) and changed it a bit so I can bolt on the pedal adapter and not remove the steering column to take the pedal off. I also moved the master a bit lower so it doesn't need as much angle on the firewall spacer. The other notable difference is that I'm working on a clip adapter to use the standard MK4 clip so I don't have to modify the master cylinder at all.

[VWsciroccoWV]

You have no idea how happy I am, and I'm sure the rest of the scirocco community, to see this is still alive! I came across this thread a while ago and saw that posts just sorta... Stopped.

Glad to see you're still doing this, that thing's gonna be a monster! Good luck!

[BennyB]

I just finished my MSc in Engineering last week, which I started in 2003. So now that I'm done, I get to work on the Scirocco again. It was a self imposed rule (sometimes broken) to stimulate the 'gumption' required to finish writing my thesis. So if I can hold off building a second bathroom for a while, I should be able to get moving on this.

[atoson]

Congratulation! Long time coming

[BennyB]

Thanks. If anyone is ever interested in reading about a "Control System and Simulation Design for an All-Wheel-Drive Formula SAE Car Using a Neural Network Estimated Slip Angle Velocity"
here is the link: http://hdl.handle.net/10214/3974

I finished the clip bracket tonight:


Final pieces to make (for the clutch) are the engine side angle bracket with a slight taper of about 3 deg, and the inside firewall reinforcing plates.

[d-bot]

The clip in MC is a great idea. I've thought about doing it that way in the past but always threaded the MC push rod instead and added a rod end. Keep up the good progress

[definition56]

Thanks. If anyone is ever interested in reading about a "Control System and Simulation Design for an All-Wheel-Drive Formula SAE Car Using a Neural Network Estimated Slip Angle Velocity"
here is the link: http://hdl.handle.net/10214/3974

I finished the clip bracket tonight:


Final pieces to make (for the clutch) are the engine side angle bracket with a slight taper of about 3 deg, and the inside firewall reinforcing plates.

Just speed read that. So he's using an ECU to control how the car handles.....couldn't he just say that? Neural Network estimated slip angle velocity?....sheesh.

Great build btw.

[tnesh]

[BennyB]

The clip in MC is a great idea. I've thought about doing it that way in the past but always threaded the MC push rod instead and added a rod end. Keep up the good progress

If I did it again, I would go that way, since then there is an easy depth adjustment. The clip was more of a pain to make than I expected. The bar stock I was going to machine it from was too hard and killed a cutter, so I switched it up an bent a U channel from 2mm sheet steel and machined the slots after welding it to the base piece.

I started making some adapters to connect the slave bleeder and master to -4AN fittings. I could have spliced the piece of line I have but don't have easy access to 6mm bubble flare fittings.

I'm making an extra set while I'm at it( if anyone else goes this route).
I got stuck here because I need to buy a thinner tool to cut the grooves.

[websaabn]

amazing work, Motivates me to get out in the garage and get to work on my Europa!

[WRC_413X]

Awesome fab work, keep it going!